SwissTech - Retention & submission requirements handbook by SwissTech

PPAP SUBMISSION REQUIREMENTS GUIDE

PPAP HANDBOOK

2014 HANDBOOK

SWISS PRECISION TECHNOLOGY SUCCES LIES IN THE QUALITY OF DETAILS SwissTech Automotive GmbH

Document: QD-PSRG-Rev.1.0

2|52 SwissTech Automotive GmbH

Marketing department

PPAP SUBMISSION REQUIREMENTS GUIDE (PSRG Handbook)

REVISION HISTORY

Revision

Date

Description of Changes

Revision 0

November 15th, 2013

Initial release PSRG document

Revision 1.0

January 13th, 2014

Review and design modification

Reviewed and approved by

CEO / President SwissTech Automotive GmbH

___________________________ Edwin B. Abbink

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

3|52 TABLE OF CONTENTS

Copyright & Disclaimer ................................................................................................................................. 4-5

PART 1. 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

General Summary of PPAP Requirements .................................................................................................. 6 Production Part Approval Process (PPAP) ...................................................................................................... 6 PPAP definition:............................................................................................................................................... 6 Production Part Approval Process (PPAP) ...................................................................................................... 6 Explanation of PPAP ....................................................................................................................................... 6 Purpose of PPAP............................................................................................................................................. 6 When is PPAP Required? ............................................................................................................................... 7 PPAP Approval ................................................................................................................................................ 7 Benefits of PPAP Submission ......................................................................................................................... 7 Production Run ................................................................................................................................................ 7

PART 2. 1. 2. 2.1 2.2 2.3 2.4 2.5 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12 2.2.13 2.2.14 2.2.15

Specific Summary of SwissTech PPAP Requirements .............................................................................. 7 Appendix 1. PPAP Submission Requirements (PSR)...................................................................................... 7 Summary of the PPAP Submission Requirements Elements .......................................................................... 9 Design Records Drawings ............................................................................................................................... 9 Engineering Change Notification – (ECN) if any or required ........................................................................... 9 SwissTech Engineering Approval .................................................................................................................... 9 Design DFMEA – Design Potential Failure Mode and Effects Analysis – (DFMEA) ........................................ 9 Process Flow Diagrams / Process Flow Chart – (PFD) .................................................................................. 9 Process FMEA – Process Potential Failure Mode and Effects Analysis – (PFMEA) ....................................... 9 Control Plan Process – Product Control Plan – (CPLAN).............................................................................. 10 Measurement System Analysis Studies – (Gage R&R, accuracy, bias, linearity, stability) ............................ 10 Dimensional Results, First Article Dimensional Layout Results – (FAIR) ...................................................... 10 Material, Performance Test Results Lab & Functional Results – (PPAMR / PPAMT) ................................... 11 Initial Process study - Capability Studies – (Cpk/Ppk) ................................................................................... 11 Laboratory scope and accreditation............................................................................................................... 11 Appearance Approval Report – (AAR)........................................................................................................... 11 Sample Product for layout inspection – (ISIR) Initial Sample Inspection Report ........................................... 12 Master Sample .............................................................................................................................................. 12 Checking Aids................................................................................................................................................ 12 Record of Compliance – (RoC)...................................................................................................................... 12 Part Submission Warrant – (PSW) ................................................................................................................ 12

Part 3. 1. 2. 3. 4. 5. 6. 7.1 7.2 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Detailed explanation of SwissTech PPAP Requirements ....................................................................... 13 Definition of Risk............................................................................................................................................ 13 Submission Level Requirements ................................................................................................................... 13 PPAP Status .................................................................................................................................................. 13 Electronic Submission Requirements ............................................................................................................ 13 SwissTech PPAP Workbook ......................................................................................................................... 13 Part Submission Warrant – (PSW) ................................................................................................................ 14 Deviation Authorization Request – (DAR) ..................................................................................................... 16 Supplier Daviation Request – (SDR) ............................................................................................................. 16 Run @ Rate – (R@R) ................................................................................................................................... 19 Process Flow Diagram .................................................................................................................................. 21 Failure Mode and Effects Analysis (FMEA) ................................................................................................... 23 Control Plan ................................................................................................................................................... 30 Measurement Analysis System (MSA) .......................................................................................................... 32 Dimensional Results ...................................................................................................................................... 39 Records of Material / Performance Test results............................................................................................. 41 Initial Process Study ...................................................................................................................................... 43 Qualified Laboratory Documentation ............................................................................................................. 46 Appearance Approval Report (AAR).............................................................................................................. 48 Sample production Parts ............................................................................................................................... 50 PPAP Summery............................................................................................................................................. 50

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4|52 COPYRIGHT & DISCLAIMER – AVIS DE NON RESPONSABILITÉ – ОТКАЗ ОТ ОТВЕТСТВЕННОСТИ – ΑΠΟΠΟΙΗΣΗ Copyright © SwissTech Automotive GmbH. All rights reserved. Published and edited by SwissTech Automotive GmbH. Reproduction of the contents of this catalogue for any commercial usage, in whole or in part, including numbers and/or illustrations, without the express written permission of the legal department from the publisher is strictly prohibited. The use of (vehicle) brand names and OE numbers are for cross reference purposes only. The products presented are independent aftermarket replacements products. It is prohibited to mention any of these OE (reference) numbers, brand names or trademarks on invoices or shipping documents towards vehicle owners. All other brands and product names contained herein may be trademarks or registered trademarks of their respective owners. SwissTech Automotive GmbH in any case excluded with the owners of such marks of any kind. The published products in this catalogue are not endorsed and/or authorized by any of the trademark owners. We strive to deliver detailed perfection and we have been made every effort to ensure that the contained information in this catalogue is complete and correct. But however, the publisher cannot warrant that and shall not be liable for any (consequential) damages incurred as a result of its use. We reserve the right to modify technical specifications or information contained in this catalogue – without any individual adequate prior notice.

Copyright © SwissTech Automotive GmbH. Tous droits réservés. Publié et édité par SwissTech Automotive GmbH. La reproduction du contenu de ce catalogue - en tout ou en partie, y compris les numéros soit/ou des images - pour un usage commercial sans l'autorisation écrite expresse de la Direction juridique de l'éditeur est strictement interdite. L'utilisation de fabricant noms de marque et les numéros de pièces d'origine sont inclus uniquement à des fins de comparaison. Les produits présentés sont des pièces de rechanges indépendants. Il est interdit à l'un de ces fabricants numéros originaux de pièces, des noms de marque ou des marques oublier les factures et bons de livraison vers les propriétaires de véhicules. Tous les autres noms de marques et de produits mentionnés ici sont des marques ou des marques déposées de leurs propriétaires respectifs peuvent être. SwissTech Automotive GmbH n'est pas liée à des entités revendiquant les marques de toutes sortes. La publiés dans ce catalogue ne sont pas parrainés ou approuvés par l'un des propriétaires. Nous nous efforçons de la perfection détaillée et nous avons fait tous les efforts pour s'assurer que les informations contenues dans ce catalogue sont complètes et correctes. Bien que les éditeurs qui ne peuvent pas garantir et n'assume aucune responsabilité ou responsabilité découlant de dommages intérêts (indirects) d'utilisation. Nous nous réservons le droit de modifier les spécifications techniques ou des informations contenues dans ce catalogue - aucun autre avis individuel approprié. Защищенный авторским правом © SwissTech Automotive GmbH. Все права защищены. Опубликовано под редакцией SwissTech Automotive GmbH.Воспроизведение содержания данного каталога - в целом или в части, в том числе цифр и/или иллюстраций - для любого коммерческого использования без письменного разрешения юридического отдела издательства строго запрещено. Использование (транспортное средство) торговых марок и оригинальные номера детали включены только в справочных целях. Продукты, представленные независимые запасные части.Одним из части-(эталонных) чисел оригинального изготовителя, наименования или торговые марки на счета-фактуры или транспортных документов на владельцев транспортных средств Все остальные марки и названия продуктов, содержащиеся здесь, являются торговыми марками или зарегистрированными торговыми марками их соответствующих владельцев. SwissTech Automotive GmbH ни в коем случае исключено владельцев этих брендов вообще. Опубликованные продукты в этом каталоге не одобрил и/или одобрена одним из владельцев товарных знаков. Мы стремимся к подробным совершенства и сделали все возможное, чтобы гарантировать, что информация, содержащаяся в этом каталоге является полной и правильной. Но тем не менее, издатель не может гарантировать и не несет ответственности за любые (косвенные) убытки, связанные с его использованием. Мы оставляем за собой право изменять технические характеристики или информацию в этом каталоге - без адекватного индивидуального уведомления. Auteursrechtelijk beschermd © SwissTech Automotive GmbH. Alle rechten voorbehouden. Gepubliceerd en uitgegeven door SwissTech Automotive GmbH. Reproductie van de inhoud van deze catalogus - geheel of gedeeltelijk, inclusief getallen en/of illustraties - voor enig commercieel gebruik, zonder de uitdrukkelijke schriftelijke toestemming van de juridische afdeling van de uitgever is strikt verboden. Het gebruik van het (voertuig) merknamen en originele onderdelen nummers zijn enkel voor referentie doeleinden opgenomen. De gepresenteerde producten zijn onafhankelijke vervangingsonderdelen. Het is verboden om een van deze fabrikant originele onderdelen- (referentie) nummers, merknamen of handelsmerken op facturen of vervoersdocumenten naar de eigenaars van voertuigen te vermelden. Alle andere merken en productnamen welke hierin vervat zijn mogelijk handelsmerken of gedeponeerde handelsmerken van hun respectieve eigenaars. SwissTech Automotive GmbH is geenszins gelinieerd aan de eigenaren van deze merken in welke aard dan ook. De gepubliceerde producten in deze catalogus zijn niet onderschreven en/of goedgekeurd door een van de eigenaren van de handelsmerken. Wij streven naar gedetailleerde perfectie en hebben alle inspanningen geleverd om ervoor te zorgen dat de opgenomen informatie in deze catalogus volledig en juist is. Doch echter kan de uitgever dit niet garanderen en is derhalve niet aansprakelijk voor eventuele (gevolg) schade als gevolg van het gebruik ervan. Wij behouden ons het recht voor om technische specificaties of informatie in deze catalogus te wijzigen - zonder voorafgaande individuele passende kennisgeving. SwissTech Automotive GmbH © telif hakkı. Tüm hakları saklıdır. Yayın ve SwissTech Automotive GmbH tarafından düzenlenebilir. Tamamen veya kısmen, numaraları ve / veya çizimler dahil olmak üzere - bu kataloğun içeriğinin çoğaltılması yayıncı hukuk departmanının yazılı izni olmadan herhangi bir ticari kullanım için kesinlikle yasaktır. Marka isimleri ve orijinal parçalar numaralarının kullanımı sadece referans amaçlı yer almaktadır. Sunulan ürünler bağımsız yedek parça bulunmaktadır. Bu söz yasaktır. Araç sahiplerine fatura veya taşıma belgelerinde orijinal üreticinin parça-(referans) numaraları, adları veya ticari markalarından biri Burada yer alan tüm diğer markalar ve ürün adları, kendi sahiplerinin ticari markaları veya tescilli ticari markalarıdır. SwissTech Automotive GmbH olursa olsun bu markaların sahipleri hüküm hiçbir şekilde. Bu katalogda yayınlanan ürünler kabul ve / veya ticari marka sahipleri tarafından onaylanmış değildir. Biz detaylı mükemmellik için çalışıyoruz ve bu katalogda yer alan bilgilerin tam ve doğru olmasını sağlamak için her türlü çabayı yaptık. Ama ancak, yayıncı garanti değil ve onun kullanımından kaynaklanan herhangi bir (dolaylı) zararlardan sorumlu değildir yapabilirsiniz. Biz bu katalogda teknik özellikleri veya bilgileri değiştirme hakkını saklı tutarız - Bireysel yeterli haber vermeden.

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5|52 ABLEHNUNG – ESCLUSIONE DI RESPONSABILITÀ – RENUNCIA – ZASTRZEŻENIE –

‫شروط‬

– 免責聲明

Urheberechtlich geschützt © SwissTech Automotive GmbH. Alle Rechte vorbehalten. Veröffentlicht und von SwissTech Automotive GmbH bearbeitet. Die Vervielfältigung des Inhalts dieses Katalogs - im Ganzen oder in Teilen, einschließlich Zahlen und/oder Abbildungen - für kommerzielle Nutzung ohne die ausdrückliche schriftliche Genehmigung der Rechtsabteilung des Verlages ist streng verboten. Die Verwendung von Hersteller Markennamen und Original-Teilenummern sind nur zu Vergleichswecken enthalten. Die präsentierten Artikel sind unabhängige - Nachbau - Ersatzteile. Es ist verboten, einem dieser Hersteller Original-Teilenummern, Markennamen oder Warenzeichen, die auf Rechnungen oder Lieferscheine in Richtung Fahrzeughalter zu erwähnen. Alle anderen Marken -und Produktnamen, die hier enthalten sind, können Marken oder eingetragene Warenzeigen ihrer jeweiligen Eigentümer sein. SwissTech Automotive GmbH ist nicht mit die Eigentümer dieser Marken jeglicher Art verbunden. Die in diesem Katalog veröffentlichten Produkte werden weder unterstützt noch von einem der Inhaber genehmigt. Wir streben nach Detaillierte Perfektion und haben alle Anstrengungen unternommen, um sicherzustellen, dass die enthaltenen Informationen in diesem Katalog vollständig und richtig sind. Obwohl der Verlag dass nicht garantieren kann und übernimmt keine Verantwortung oder Haftung, die als (Folge-)Schäden der Nutzung entstehen. Wir behalten uns das Recht vor, technische Spezifikationen oder in diesem Katalog enthaltenen Informationen zu ändern - ohne weitere Einzel entsprechende Ankündigung. Copyrighted © SwissTech Automotive GmbH. Todos los derechos reservados. Publicado por el SwissTech Automotive GmbH. La reproducción de los contenidos de este catálogo - en su totalidad o en parte, incluyendo figuras y / o imágenes - para uso comercial sin el consentimiento expreso y por escrito del Departamento Legal de la editorial está terminantemente prohibida. El uso de marcas de fabricante y los números de las piezas originales se incluyen sólo a efectos de comparación. Los productos presentados son piezas de recambio independientes. Está prohibido hablar. Una de las partes(referencia) los números del fabricante original, nombres o marcas registradas en las facturas o documentos de transporte con los propietarios de los vehículos. Todas las demás marcas y nombres de productos mencionados en este documento son marcas comerciales o marcas comerciales registradas de sus respectivos propietarios pueden ser. SwissTech Automotive GmbH no está relacionado con las entidades propietarias de las marcas de ningún tipo. La publicación de este catálogo no es patrocinada o aprobados por uno de los propietarios. Nos esforzamos para la perfección detallada y hemos hecho todo lo posible para garantizar que la información contenida en este catálogo es completos y correctos. Aunque los editores que no pueden garantizar y no acepta ninguna responsabilidad u obligación que surge como un (indirectos) una indemnización de uso. Nos reservamos el derecho de modificar las especificaciones técnicas o información contenida en este catálogo - sin aviso apropiado persona adicional. Copyrighted © SwissTech Automotive GmbH. Tutti i diritti riservati. Pubblicato e curato da SwissTech Automotive GmbH. La riproduzione del contento di questo catalogo - in tutto o in parte, compresi i numeri e/o illustrazioni - per qualsiasi uso commerciale senza il permesso scritto del dipartimento legale della casa editrice è severamente vietato. L'uso delle (veicolo) nomi di marca del produttore e nomi di marchi e numeri di pezzi originali sono incluse solo a scopo di riferimento. I prodotti presentati sono pezzi di ricambio indipendenti. E 'vietato parlare. Uno di parti (di riferimento) numeri a quelle originali, nomi o marchi di fatture o documenti di spedizione ai proprietari dei veicoli Tutti gli altri marchi e nomi di prodotti contenuti nel presente documento sono marchi o marchi registrati dei rispettivi proprietari. SwissTech Automotive GmbH non è in alcun modo escluso i proprietari di questi marchi di sorta. I prodotti pubblicati in questo catalogo non sono approvati e/o approvati da uno dei proprietari dei marchi. Ci impegniamo per la perfezione dettagliato e abbiamo fatto ogni sforzo per garantire che le informazioni contenute in questo catalogo sono complete e corrette. Ma comunque, l'editore non può garantire e non è responsabile per eventuali danni (conseguenti) derivanti dal suo utilizzo. Ci riserviamo il diritto di modificare le specifiche o informazioni in questo catalogo - senza un adeguato preavviso individuale. Prawami autorskimi © SwissTech Automotive GmbH. Wszelkie prawa zastrzeżone. Opublikowane i edytowane przez SwissTech Automotive GmbH. Powielanie zawartości tego katalogu - w całości lub w części, łącznie z numerami i/lub ilustracji - dla celów komercyjnych bez pisemnej zgody działu prawnego wydawcy jest zabronione. Wykorzystanie (pojazd) markami oraz oryginalne numery części zawarte są jedynie w celach informacyjnych. Produkty prezentowane są niezależne części zamienne. Zabrania się wspomnieć. Jedna z części - (referencyjnych) numerów oryginalnego producenta, nazwy lub znaków towarowych na fakturach i dokumentach przewozowych do właścicieli pojazdów Wszystkie inne nazwy marek i produktów zawarte w niniejszym dokumencie są znakami towarowymi lub zastrzeżonymi znakami towarowymi ich właścicieli. SwissTech Automotive GmbH nie jest w żaden sposób wykluczyć właścicieli tych marek w ogóle. Publikowane produkty w katalogu nie są zatwierdzone i/lub zatwierdzone przez jednego z właścicieli znaków towarowych. Dążymy do doskonałości, a nie szczegółowe dołożył wszelkich starań, abyinformacje zawarte w tym katalogu są kompletne i prawidłowe. Ale jednakwydawca nie może zagwarantować i nie ponosi odpowiedzialności za (pośrednie) szkody wynikające z ich wykorzystania. Zastrzegamy sobie prawo do zmiany specyfikacji i informacji w katalogu - bez indywidualnego odpowiedniego powiadomienia. ‫ بما في ذلك‬،‫ كليا أو جزئيا‬- ‫ استنساخ محتويات هذا الكتالوج‬.‫ نشرت وحرره السويسري للتكنولوجيا السيارات‬.‫ جميع الحقوق محفوظة‬.‫حقوق الطبع والنشر © السويسري للتكنولوجيا السيارات‬ ‫ يتم تضمين استخدام األسماء التجارية المصنعة وأرقام قطع غيار‬.‫ ألغراض تجارية دون الحصول على إذن كتابي صريح من اإلدارة القانونية من الناشر ممنوع منعا باتا‬- ‫ أو الصور‬/ ‫أرقام إما‬ ‫ األسماء التجارية أو العالمات التجارية أن أذكر الفواتير‬، ‫ يحظر احدة من هذه الشركات المصنعة أرقام الجزء األصلي‬.‫ قطع الغيار‬- ‫ طبق‬- ‫ البنود المعروضة مستقلة‬.‫أصلية فقط ألغراض المقارنة‬ ‫ السويسري‬.‫ جميع أسماء المنتجات واألصناف األخرى الواردة في هذه الوثيقة هي عالمات تجارية أو عالمات تجارية مسجلة ألصحابها يمكن أن يكون‬. ‫أو المالحظات تسليم نحو أصحاب المركبات‬ ‫ ونحن نسعى جاهدين لتحقيق‬. ‫ و نشرت في هذا الكتالوج ال تتم رعايتها أو الموافقة عليها من قبل أحد مالكي‬.‫ غير متصل إلى الكيانات المالكة لهذه العالمات من أي نوع‬.‫للتكنولوجيا السيارات‬ ‫ على الرغم من أن الناشرين ال يمكن ضمان وال تتحمل أي مسؤولية أو تبعة الناشئة باعتبارها‬. ‫الكمال مفصلة و بذلوا كل جهد ممكن لضمان أن المعلومات الواردة في هذا الدليل هي كاملة وصحيحة‬ .‫ ال مزيد من إشعار مناسب الفردية‬- ‫ نحن نحتفظ بالحق في تغيير المواصفات الفنية أو المعلومات الواردة في هذا الكتالوج‬.‫( التبعية) أضرار من استخدامها‬ 版权所有©SwissTech Automotive GmbH。保留所有权利。出版和 SwissTech Automotive GmbH 编辑。严禁未经出版者的法律部门的明确书面许可用于商业用途 - 全部或部分内容，包括数字和/或图像 - 这个目录的内容再现。使用制造商品牌和原厂件数仅包括以作比较。所提出的项目是独立的 - 副本 - 备件。禁止这些厂家原装零件号，品牌名称或商标提发票或送货单向车主之一。此处包含的所有其它品牌和产品名称均为其各自所有者可以是注册商标。 SwissTech Automotive GmbH 未连接到声称任何形式的印记的实体。从已公布的本产品目录中没有赞助或认可的业主之一。我们追求完美细节，并已作出一切努力，以确保包含在此目录中的信息是完整和正确的。虽然这不能保证和出版商接受作为产生使用的（间接）损失不承担任何责任。我们保留随时更改本样本技术规格或信息的权利 - 没有进一步的个别适当的通知。

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6|52

PART 1. 1.

General Summary of PPAP Requirements

Production Part Approval Process (PPAP) 1.1

PPAP definition: PPAP is a set of steps followed by manufactures and suppliers to make sure that safety risks are removed from each automobile part, before gets to a distributor and consumer.

1.2

Production Part Approval Process (PPAP) SwissTech could require all levels of PPAP documentation from PPAP level 1 to PPAP level 5. In case the paperwork is not clear regarding the required PPAP level, please contact our quality team to discuss which the PPAP level is required. We have all the necessary required PPAP forms / documents for the PPAP process carried out in this PPAP Guide Workbook. The PPAP requirements are typically distinguished by level as follows: PPAP Submission Levels;     

Level 1 - Part Submission Warrant (PSW) only submitted to the customer. Level 2 - PSW with product samples and limited supporting data. Level 3 - PSW with product samples and complete supporting data. Level 4 - PSW and other requirements as defined by the customer. Level 5 - PSW with product samples and complete supporting data.

1.3

Explanation of PPAP PPAP is used in Automotive Supply Chain for establishing confidence in component suppliers and their production processes, by means of demonstrating that: "....all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate." PPAP is a standard used to formally reduce risks prior to product or service release, in a team oriented manner using well established tools and techniques. Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM AIAG’s 4th edition effective June 1, 2006 is the most recent version. PPAP has now spread to many different industries beyond automotive.

1.4

Purpose of PPAP PPAP’ purpose continues to be to provide evidence that all SwissTech engineering design record and specification requirements are properly understood by the organization. To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate. PPAP manages change and ensures product conformance!

1.5

When is PPAP Required? Suppliers are obligated to obtain PPAP approval prior to any shipment of a vehicle production lot of parts.  Development for new part(s)  Engineering change(s)  Tooling: transfer, replacement, refurbishment, or additional  Correction of discrepancy  Tooling inactive > one year  Change to optional construction or material  Sub-supplier or material source change  Change in part processing  Parts produced at a new or additional location  For bulk materials, PPAP is not required unless specified by the authorized customer representative. Note:

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PPAP is required with any significant change to product or process!

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7|52

Obtaining approval requires the supplier to provide sample parts and documentary evidence showing that:    

1.6

PPAP Approval The result of this process is a series of documents gathered in one specific location (a binder or electronically) called the "PPAP Package". The PPAP package is a series of documents which need a formal approval by the supplier and customer. The form that summarizes this package is called PSW (part submission warrant). The approval of the PSW indicates that the supplier responsible person (usually the Quality Engineer) has reviewed this package and that the customer has not identified any issues that would prevent its approbation.

1.7

Benefits of PPAP Submission       

1.8

PART 2.

The client's requirements have been understood The product supplied meets those requirements The process (including sub suppliers) is capable of producing conforming product The production control plan and quality management system will prevent non-conforming product reaching the client or compromising the safety and reliability of finished vehicles

Helps to maintain design integrity Identifies issues early for resolution Reduces warranty charges and prevents cost of poor quality Assists with managing supplier changes Prevents use of unapproved and nonconforming parts Identifies suppliers that need more development Improves the overall quality of the product & customer satisfaction

Production Run PPAP data must be submitted from a production run using: 1. 2. 3. 4.

Production equipment and tooling Production employees Production rate Production process

Note:

All data reflects the actual production process to be used at start-up!

Specific Summary of SwissTech PPAP Requirements

Appendix 1. PPAP Submission Requirements (PSR) (Supplier shall submit these required items and retain a copy of record at appropriate location)

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

PPAP SUBMISSION REQUIREMENTS

DOC. CODE

REV.

QD-PSR-I

Part Number

PPAP Production Part Approval Process

4DB.12B.4528-00 ℗

PRODUCT INFORMATION Air Brake Disc / Rotor

SwissTech │ OE Ref. № SwissTech Smart № │ Supplier Ref. № Drawing №

4DB.12B.4528-00

942 421 21 12

+T DBR-4528

ABC-123

Program Name / № Purchase Oder №

New Production Item SwissTech Q+ Disc 567890

Drawing Revision B Level Engineering Change 1234 Notification ECN/№

123456789Z

Additional Engineering Changes

Reason for Request

No Changes

Issue Date Submission Due Date № of Samples Required Drawing Rev. Level Date ECN Date

Part Description

PPAP Retention / Submission Requirements

27 June 2013 28 July 2013

Level 2

Level 1

Level 5

-for all other components/ details

Pcs.

Level 4

-for proprietary components/ details

Level 3

Design Record

01 October 2013

Required

R S Required PPAP R level is R mentioned on the PPAP R S submission Requirements R R template. R R

PPAP Requirements level check list 1

01 September 2013

Engineering Change Notification (ECN), if required

SwissTech Engineering approval, if required

Design Failure Modes effect Analysis (DFMEA) applied in special situations

Process Flow Diagrams (PFD)

Process Failure Modes and Effects Analysis (FMEA)

Control Plan (CPLAN)

Measurement System Analysis Studies (MSA)

Dimensional Results (FAIR)

10 Records of Material, Performance Test Results

11 Initial Process & Capability Studies (Cp / CpK = 1.33) for critical dimensions

12 Qualified Laboratory Documentation

13 Appearance Approval Report (AAR), If applicable

14 Sample Product for layout inspection (ISIR)

15 Master Sample - one Sample to be Identified as a Master Sample and Retained

16 Checking Aids (Fixture, gage, template, etc.)

17 Records of Compliance with SwissTech-Specific Requirements

18 Part Submission Warrant (PSW)

Bulk Material Checklist S S S Legend S = The organization shall submit to SwissTech and retain a copy of records or documentation items at appropriate locations. R = The organization shall retain at appropriate locations and make available to SwissTech upon request. * = The organization shall retain at appropriate locations and submit to SwissTech upon request. PPAP Level

Retention / Submission Requirements

Production Warrant and Appearance Approval Report) submitted to the SwissTech.

Production Warrant, product samples and (dimensional only) supporting data submitted to the SwissTech.

Production Warrant, product samples and complete supporting data submitted to the SwissTech.

Production Warrant and other requirements as defined by the SwissTech.

Production Warrant, product samples and complete supporting data reviewed at the organization’s manufacturing location. Additional or Expectation for Submission - Instructions Below Important Notes:

Document: QD-PSR-Rev.1.0

Document: QD-PSRG-Rev.1.0

All Drawings and Bill of Material (BOM) should be part of the PPAP documentation (only for service kits)

PPAP documentation and sampling should be submitted as one package at the same time.

www.SwissTech-Automotive.ch

PAGE 1 / 1

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Summary of the PPAP Submission Requirements Elements 2.1 Design Records Drawings Suppliers MUST submit a ballooned copy of the drawing that corresponds to the Dimensional, Material, and Performance Results. The drawing MUST be the official engineering released design record. The PPAP MUST meet ALL drawing requirements to be considered for approval.  When the design records, e.g. CAD/CAM math data, part drawings, specifications, are in electronic format, e.g. math data, the supplier shall produce and submit a hard copy (e.g. pictorial, GD&T sheets, drawing, specification pages, etc.) to identify measurements taken. 2.2 Engineering Change Notification – (ECN) if any or required Required only if there is any changes, which the supplier initiates.  This “Engineering Change Notification” (ECN) is required SwissTech approval in case of any material, drawing, or process changes. This record provides history for the customer on the specific reasons for the changes.  SwissTech MUST be informed, via written documentation, of the supplier's plans for changes PRIOR to the actual change. This documentation must include the part numbers affected, the description of the change, the reason(s) for the change, the requested timing for the change, and the supplier representative's contact information, signature and date.  Sufficient time MUST be given for customer review.  Failure to follow through with this requirement places SwissTech at risk and will result in disciplinary action.  The supplier shall have any authorized engineering change documents for those changes not yet recorded in the design record but incorporated in the product, part or tooling. 2.3 SwissTech Engineering Approval Where specified by SwissTech, the organization have evidence of customer engineering approval including approval for parts, tooling, product or processes. 2.4 Design DFMEA – Design Potential Failure Mode and Effects Analysis – (DFMEA) ONLY applicable when the supplier has design responsibility. A tool used when designing a component, system, process, etc. to assure, to the extent possible, that all design potential failure modes (Design related) and their associated causes/mechanisms have been considered and addressed. Note: Retain at supplier facility. Must be available for SwissTech review at any time. 2.5 Process Flow Diagrams / Process Flow Chart – (PFD) This record is used to verify that the supplier has thoroughly evaluated and analyzed the total manufacturing or assembly process, from start to end, for all possible causes of variation (i.e. machines, materials, methods, etc.) and has organized the process in such a way as to eliminate/reduce the effect these variations will have on the overall quality system.  This document shall flow smoothly into the supplier Control Plan and FMEA. Part/Process Numbers and Process Name/Operation Descriptions should carry over and be consistent on all three documents.  Title blocks must be complete and must reference all, unique, SwissTech information.  Please use the standard SwissTech Process Flow Diagram Forms or an approved AIAG Form.  In some cases SwissTech will allow Family Group PFD's, FMEA's and Control Plan - When this is agreed upon, the supplier shall have a reference attachment for all part numbers and individual part differences of the parts in the Family Grouping. 2.2.3

Process FMEA – Process Potential Failure Mode and Effects Analysis – (PFMEA) To assure that all potential failure modes and the effects they have on a process have been considered and eliminated/addressed. Please note the following:  If there are no recommended actions you must state “none” in the recommended actions column.  Do not use “Operator Error” as a potential failure. The failure is rooted to a process or system.  A PFMEA should be created by a team which has representation from every area of the process.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

10 | 5 2

   

All Special Characteristics (e.g., critical, key, significant) must be ID'd/addressed on the PFMEA. Any issue, customer or internal, will require review/adjustment of R.P.N. numbers. The PFMEA is a living document that should be utilized/updated for the life of the product. In some cases SwissTech will allow Family Group PFD's, FMEA's and Control Plan - When this is agreed upon, the supplier shall have a reference attachment for all part numbers and individual part differences of the parts in the Family Grouping.

2.2.4

Control Plan Process – Product Control Plan – (CPLAN) To aid in the manufacture of quality products according to customer requirements. A structured approach for must be used for the design, selection, and implementation of value-added control methods for the total system. It provides a written summary description of the systems used in minimizing process and product variation.  All Special Characteristics (e.g., critical, key, significant, etc.) must be indentified and addressed on the CPLAN.  The CPLAN is a living document that should be used and updated for the life of the product.  Any changes made to the product Control Plan must have “written” SwissTech Approval and may result in a resubmission of the PPAP.

2.2.5

Measurement System Analysis Studies – (Gage R&R, accuracy, bias, linearity, stability) The purpose of this record is to verify that the Gage or measurement system is capable of accurately assessing the quality of the parts.  Measurement System Analysis Studies must be submitted with ALL Initial Process Studies.  Gage R&R, Bias, Linearity, & Stability must be submitted when applicable. Definitions: Please reference the Measurement Systems Analysis manual. Acceptance Criteria: Gage R&R - < 10% is Acceptable, 10% to 30% require based on importance, and > 20 is reject able

Corrective action is necessary for all reject able items. >>> Measurement System Analysis Studies must be included with all Initial Process Studies for ALL engineering changes that could have an effect on the Special Characteristics (e.g., critical, key, significant, etc.) that are called out on the Drawing or Control Plan. They must also be submitted if the gage is modified for any reason. If it is unclear please contact SwissTech Automotive. 

2.2.6

Attribute Studies (If Applicable) will be performed on 20 parts, with 2 operators and 2 trials. To meet acceptance criteria all results from the study must "PASS".

Dimensional Results, First Article Dimensional Layout Results – (FAIR) This record is used to verify the parts meet all of the dimensional requirements called out on the Drawing and Control Plan.  If production parts will be produced from more than one cavity, mold, tool, die, pattern, or production process, the supplier shall complete a dimensional evaluation on a minimum of one part from each unique process/variation (Including color, if applicable, for certain process') The specific cavities, molds, line, etc. shall then be identified on the PSW & on the Dimensional Results Report.  

Document: QD-PSRG-Rev.1.0

All dimensions, characteristics and specifications noted on the Drawing and Control Plan should be listed in a convenient/organized format with the actual results recorded. All records shall be submitted on the SwissTech Dimensional Results Form.

www.SwissTech-Automotive.ch

11 | 5 2

2.2.7

Material, Performance Test Results Lab & Functional Results – (PPAMR / PPAMT) This record is used to verify that the parts meet all of the Material and/or performance requirements / specifications called out on the Drawing and Control Plan.  All dimensions, characteristics, and specifications noted on the Drawing and control plan should be listed in a convenient/organized format with the actual results recorded.  Material Testing Results, Performance Testing Results, and other engineering requirements on the design record shall be less than one year old at the time of the initial submission. This data shall be updated for engineering changes that affect the original data. The supplier shall also maintain and update all testing data for each lot of material. When PPAP is requested for an engineering change, the supplier shall submit the testing data that corresponds to the material for the change.

2.2.8

Initial Process study - Capability Studies – (Cpk / Ppk) The purpose of this record is to determine if the production process will produce product that meets the Customer's requirements.  Suppliers must submit with their Cpk results at least 30 data results that the Cpk results were derived from or the PPAP will not be considered for approval. Also include a copy of the histogram (Graphs).  Supplier MUST submit Initial Process Study for all Special Characteristics (e.g., critical, key, The results significant, etc.) that are called out on the Drawing or Control Plan. Studies must be submitted that are representative of each unique production process, e.g. duplicate assembly line and/or work cell, each position of a multiple cavity die, mold, tool, or pattern, etc.  The acceptance criteria for Capability Studies is as follows: * Short term study - must meet > or = to 1.67 Cpk and > = 2.00 Cp * Long term study - must meet > or = to 1.33 Cpk and > = 2.00 Cp 



If Cpk falls between 1.33 and 1.67 (Short Term Study), a corrective action plan and interim revised Control Plan (normally providing for 100% inspection) must be developed by the supplier and approved by the customer prior to approval. New studies MUST be performed after corrective action is implemented and must be included in a revised PPAP submission. ALL Initial Process Studies must be accompanied by Measurement System Analysis Studies.

>>> Initial process studies must be performed for ALL engineering changes that could have an effect on the Special Characteristics (e.g., critical, key, significant, etc.) that are called out on the Drawing or control Plan. If it is unclear please contact your SwissTech Automotive buyer. 2.2.9

Laboratory scope and accreditation The purpose of this record is to verify that the supplier has used an Accredited Laboratory/Testing Facility to perform all Material, Functional, and Performance testing called out on the Drawing and Control Plan.     

2.2.10

This Record must be submitted with ALL testing data. This includes ALL standards and specifications called out on the Drawing and CPLAN. Records must be submitted by the Laboratory that actually performed the testing. Accreditation certification must NOT be out-dated. Testing facilities that are strictly Laboratory facilities by nature must submit Laboratory Scope and Accreditation because they are not able to acquire QS9000 Registration.

Appearance Approval Report – (AAR) For Appearance Items ONLY Submitted with PPAP and sample parts for the customer to sign, verifying parts are verifying that the parts meet all aesthetic criteria.  Must have Spectrophotometer data readings. (Dl*, Da*, Db*, DE*, CIE LAB)

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

12 | 5 2

2.2.11

Sample Product for layout inspection – (ISIR) Initial Sample Inspection Report Submitted for Appearance and Functional evaluation. Six samples are required with each PPAP submission 

   

A few of the parts used for dimensional verification shall be submitted. These shall be labelled with part#, cavity, revision, tool #, etc. & with a sample number that corresponds to the Dimensional Report. Suppliers shall submit samples that represent each unique cavity, mold, line, etc. Sample parts sent in shall be from a significant "production" run as outlined in the AIAG PPAP Manual. All Special Characteristics (e.g., critical, key, significant, etc.) must be ID'd / addressed on the CPLAN The CPLAN is a living document that should be utilized/updated for the life of the product. Any change made to the product must have “written” in the Product control plan

2.2.12

Master Sample The supplier shall retain a master sample for the same period as the production part approval records or until a new master sample is produced for the same customer part number for customer approval, or where a master sample is required by the design record, Control Plan or inspection criteria, as a reference or standard. The master sample shall be identified as such, and shall show the SwissTech approval date on the sample. The supplier shall retain a master sample for each position of a multiple cavity die, mold, tool or pattern, or production process unless otherwise specified by SwissTech.

2.2.13

Checking Aids If requested by SwissTech, the supplier must submit with the PPAP submission any part-specific assembly or component checking aid. The supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The supplier shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. The supplier shall provide for preventive maintenance of any checking aids for the life of the part. 

Measurement System Analysis Studies (e.g. Gage R&R, accuracy, bias, linearity, stability) shall be conducted in compliance with SwissTech requirements (see # 8).

2.2.14

Record of Compliance – (RoC) The supplier shall have records of compliance to all applicable SwissTech specific requirements. For bulk materials, applicable SwissTech requirements shall be documented on the Bulk Materials Requirements Checklist.

2.2.15

Part Submission Warrant – (PSW) To clearly state to the Customer the reason for your submission. Take special note of the following:        

Document: QD-PSRG-Rev.1.0

Record part revision level to the right of the part# (Drawing revision & Part revisions may be different. Supplier Must mark “yes” or “no” to meeting all Drawing requirements & sign the PSW. Part Weight to be expressed in kilograms to four significant decimal places (0.0000). Reminder- Part weight is determined by an average of ten randomly selected parts. Identify whether the part does or does not contain Reportable/Restricted Substances. Suppliers are encouraged to mark plastic parts with the appropriate ISO symbols to designate type of polymer & filler used in the part. Identify on the PSW ("Yes" or "No") The specific Molds/Cavities/Prod. Process' pertaining to the PPAP shall be ID'd on the PSW. Record the Production Rate at which the PPAP samples were produced on the PSW. All checking aides used in the everyday processing of a part shall be identified on the PSW.

www.SwissTech-Automotive.ch

13 | 5 2

Part 3. 1.

Detailed explanation of SwissTech PPAP Requirements

Definition of Risk 1.1

High Risk  Parts associated with multiple critical features, complex design, drawings marked up with SRC (Safety Critical Component) or high end technology that is not yet established in the general manufacturing environment.  Supplier’s quality system and/or quality performance is not to SwissTech satisfaction.

1.2

Medium Risk  Parts that have at least one critical feature

1.3

Low Risk  Parts that have no critical features and can be manufactured by any manufacturer in the commodity category  Supplier’s quality system and quality performance are acceptable

Submission Level Requirements 2.1

New Parts Level 2 is required for Low Risk Parts Level 3 is required for Medium and High Risk Parts

2.2

Part Changes Level 3 is required for Parts produced at a new or additional location Supplier Quality Excellence will define the level required for all other changes Note: SwissTech reserves the right to redefine the submission level required

PPAP Status 3.1

Approved The part meets all SwissTech requirements Supplier is authorized to ship production quantities of the part

3.2

Interim Approval Permits shipment of part on a limited time or piece quantity basis

3.3

Rejected The part does not meet SwissTech requirements, based on the production lot from which it was taken and/or accompanying documentation Any production quantities (lot/batch) may not be shipped prior SwissTech Approval

Electronic Submission Requirements SwissTech is not been set up for electronic PPAP submissions. The use of paper submission must have prior approval by the SQE. Submission must be received on or prior to the PPAP due date. 4.1

Review and Approval Process SwissTech will attempt to review and provide feedback within 5 business days

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

14 | 5 2

SwissTech PPAP Workbook 5.1

What is the SwissTech PPAP Workbook? An Excel spreadsheet containing templates of the documents suppliers are required to submit to SwissTech.

5.2

Why use the SwissTech PPAP Workbook?  Simplifies the process for suppliers by serving as a “checklist” of what needs to be submitted to SwissTech Automotive GmbH  Reduces the number of files to manage  Enables the SQE to quickly see if anything is missing

Part Submission Warrant – (PSW) 6.1

What is it? A Part Submission Warrant is a document required for all newly tooled or revised products in which the supplier confirms that inspections and tests on production parts show conformance to SwissTech requirements.

6.2

Objective or Purpose Used to:  document part approval  provide key information  declare that the parts meet specification

6.3

Applicability A signed Production/Part Submission Warrant is required prior to shipping any production parts.

6.4

Production Warrant Checklist  Must be completely filled out  Must be signed by the supplier  P/N must match the PO  Submitted at the correct revision level  Submitted at the correct submission level  Specify the reason for submission

6.5

Appendix 2. (Below shown a PSW document) This is the form that summarizes the whole PPAP package. This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer. There is a section that asks for "results meeting all drawing and specification requirements: yes/no" refers to the whole package. If there is any deviations the supplier should note on the warrant or inform that PPAP cannot be submitted.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

PART SUBMISSION WARRANT (PSW)

DOC. CODE

REV.

QD-PSW-I

PSW Number 10001

PRODUCT INFORMATION Part Description

Safety and/or Government Regulations

Air Brake Disc / Rotor

SwissTech Part №

Supplier ABC-123 Ref. № OE Ref. № 942 421 21 12

4DB.12B.4528-00 ℗

SwissTech Smart №

+T DBR-4528

Drawing №

Application

123456789Z

Checking Aid Eng. Change Level Checking Aid №

E/c Issue Date

N/A

Program Name

N/A

ORGANISATION MANUFACTURING INFORMATION 101

Organisation Name & Supplier

Vendor code

Einbahnstrasse

Street address

Number

City

8702

Region

34.7

UOM

1234

No PO-00001

PO Issue 25 August 2013 Date Drawing B Rev. Level ECN Issue 28 July 2013 Date

No Changes

SWISSTECH SUBMITTAL INFORMATION

Preud'homme d'Hailly de Nieuport

Zürich

430 x 430 x 132.5

Engineering Change Notification ECN/№ Additional Engineering Changes

76543

Zolikon

SwissTech Q+ Disc

Part Dimensions L x W x H [mm] Part Net Weight [Kg]

MERCEDES-BENZ

Yes PO №

Switzerland

Postal Code

Country

RESTRICTION OF HAZARDOUS SUBSTANCE (RoHS) < Mandatory > < As Applicable > RoHS Compliant DFAR Compliant Non-Compliant Non-Compliant if Non-Compliant please specify: if Non-Compliant please specify:

John McKinsey

Purchase@SwissTech.ch

Purchase Manager

E-Mail Address

George Lycklama à Nijeholt

Quality@SwissTech.ch

Supplier Quality Manager

E-Mail Address

Louis de Charon de Saint Germain

Quality@SwissTech.ch

Quality Supervisor

E-Mail Address

INTERNATIOAL MATERIAL DATA SYSTEM (IMDS) Automotive Suppliers only Global Automotive Declarable Substance List 56789 Node Number: 54321 Mode Submittal Required No Declarable Substances

MATERIALS REPORTING Has Customer-required Substances of Concern information is been reported?

Yes

n/a

Yes

n/a

Submitted by IMDS or other Customer format: Are Polymeric parts identified with appropriate ISO making codes? REASON(S) FOR SUBMISSION (check at least one) Initial Submission (for new production parts) Engineering Change(s) Correction of Discrepancy Tooling: Transfer, Replacement, Refurbishment or additional Tooling Inactive > 1 year

Change to Optimal Construction or Material Supplier or Material Source Change Change in Part Processing Parts Products at Additional Location Other - Please Specify

REQUESTED SUBMISSION LEVEL Level 3 - Warrant with Product samples and complete supporting data submitted to SwissTech QA Department

SUBMISSION RESULTS The Results for

dimensional measurements

material and function test

These results meet all drawing and specifications requirements Mold / Cavity / Production Process

appearance criteria

Yes

statistical process package

(If "No" - Explanation below)

N/A

DECLARATION I hereby affirm that the samples represented by this Warrant are representative of our parts, which we meet by a process that meets all the applicable current revision Part Approval Process Manual Requirements . I further affirm that these samples were produced at the production rate of X Y Hours. / I also certify that documented evidence of such compliance is on file and applicable for review. I have noted any deviations from this declaration below. EXPLONATION / COMMENTS

Read, undestood and agreed

Is each SwissTech tool properly tagged and numbered?

Yes

n/a

Supplier authorized signature Name

Jacque van Nassau

Title

QA Mgr.

Phone Number +41 76 6789 001

Date:

25 August 2013

Fax No.

+41 76 6789 005

E-Mail address J.van.Nassau@HaillydeNieuport.com FOR SWISSTECH USE ONLY

Part Submission Deposition Appearance Print name

PPAP No.:

Approved 000123

Rejected

Other (Please Specify) Part Functional

Document: QD-PSW -Rev.1.0

Document: QD-PSRG-Rev.1.0

Rejected

Other

SwissTech tracking Number (Optional)

Norman d'Audenhove

SwissTech Automotive Signature

Approved

Interim Approved, Need further Tolerance improvement

Jean Paul Schwartzenberg

80661

Date:

02 October 2013

www.SwissTech-Automotive.ch

PAGE 1 / 1

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(Engineering) AUTHORIZED CHANGE REQUEST – (DAR) The supplier shall provide an authorized change request for those changes not yet recorded in the design record, but incorporated in the product, part or tooling, such as:  ECNs (must be approved, not pending)  Specifications  Feasibility studies  Supplier change requests  Sub-assembly drawings  Life or reliability testing requirements 7.1

Appendix 4. (Engineering) Deviation Authorization Request

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

DOC. CODE

REV.

QD-DAR-I

DEVIATION AUTHORIZATION REQUEST

Deviation Number ____-__-___-__

PRODUCT INFORMATION Part Description SwissTech Part № SwissTech Smart № Drawing №

REPORTING INFORMATION

Supplier ABC-123 Ref. № OE Ref. 942 421 21 12 №

Performed By (Name) Supplier (Name) Facility Location

Drawing Revision Level

Verified By (SwissTech)

Air Brake Disc / Rotor 4DB.12B.4528-00 ℗ +T DBR-4528 123456789Z

Issue Date Subm. Date PO №

Jacque van Nassau Preud'homme d'Hailly de Nieuport Vendor №

Zolikon

101

Part Number Involved

Start Date or Serial #

PO-00001 02 October 2013

Product Family Name

Air Brake Disc Rotor

Rev. Level

Part Description

WP2 BD Rotor

7654897

30 September 2013

Review Date (SwissTe

Jean Paul Schwartzenberg

OTHER PARTS INVOLVED Product Family Name

23 September 2013

Part Number Involved

End Date or Serial #

02 March 2011

Rev. Level

Part Description

Qty Affected

A976252

REASON (Check one)

23,476

DISTRIBUTION (Signatures)

1. Use parts that do not meet engineering drawing specifications.

Engineering

2. Material substitution (Add Comments/Special Instructions).

Manufacturing Eng.

3. Use parts that do not meet approved appearance standards.

Supplier Quality

4. Temporarily unable to follow standard process procedures.

Purchasing

5. Other:

Incoming Quality

Pierre Flugi van Aspermont Patrick Dumonceau Paul Von Riedesel d'Eisenbach Jacque van Nassau

EHS Manager

Corrective Actions

Other Other Product / Process Change Affects (Check all that apply) What

Dimensional

Materials

Functional

Appearance

Process

Affect

Product Safety

Customers

Inventory

Tooling

Pricing

Detailed description Consequences of Product / Process Change (If Applicable) What New material Sub-supplier Change Conceq. Need to Approve Material Source

What Change Conceq.

BILL OF MATERIAL CHANGE (BOM) Seq #

Part Number

Description

Add

Delete

N/A

FOR SWISSTECH USE ONLY Position

Name

Signature

Lead Rudolf von Hertzberg Engineer Quality Hugo Rosenthal Manager

Date 01/10/2013 29/09/2013

Position

Name

Signature

Purchasing John McKinsey Manager Quality Louis de Charon de Saint Germain Supervisor

Date 30/09/2013 02/10/2013

NOT APPROVED, REASON N OTE: Please submit this notification prior to the planned change implementation !!! Document: QD-DAR-Rev.1.0

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

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Appendix 3. Supplier Deviation Request

SUPPLIER DEVIATION REQUEST

DOC. CODE

REV.

QD-SDR-I

VENDOR-ZONE No. ____-__-___-__

Section I. To be completed by the supplier Supplier (Name)

Preud'homme d'Hailly Manufact. de Nieuport (Location)

Project Champion

Hugo von Hertzberg

Part Description

Air Brake Disc / Rotor

Purchase Order №

PO-00001

QTY in Stock Batch №

1251

12453

Check one of the boxes

Project Leader Part Number SOP Date QTY Tested Lot №

Zolikon

Requestor (Name)

Jacque van Nassau

Paul Von Riedesel d'Eisenbach

E-Mail Address

P.Eisenbach@HaillydeNieu Telephone port.com №

4DB.12B.4528-00 ℗

01 December 2013

Drawing № PSO № QTY Affected

172

Serial №

6543

This is a ONE-TIME deviation request

Request Date

25 August 2013

+41 76 6789 002

123456789Z

Drawing Revision

14431

Drawing Rev. Date

27 June 2013

78555789

E/C Date

28 July 2013

Other if applicable

This is a temporary deviation request

This is a permanent change request

A) Description of Non-conformance and/or proposed Deviation:

Design Responsibility SwissTech Automotive GmbH Supplier

B) Effect of Deviation: Deviation Type (Chec k all that apply) Dimensional

C) Reason for Deviation Request:

Material Functional Appearance

D) How the Delivery Schedule will be Affected:

Process Manufacture Location Suppliers Sub-supplier SwissTech Supplier Quality Requirements

E) How Cost will be Affected: Section II. To be completed by SwissTech DISPOSITION:

REJECTED APPROVED This lot only Temporally,

Special indication requirements Engineer name:

Effective until: Signature

Date

Quality Hugo von Hertzberg Engineer name: QE. Phone No.

Signature

Date

Buyer name

Signature

Norman d'Audenhove

Jack Parker de Ruyter

Buyer Phone No. Document: QD-SDR-Rev.1.0

Document: QD-PSRG-Rev.1.0

E-Mail

H.vonHertzberg@SwissTech.ch

30 August 2013

27 August 2013

Fax. No. Date

J.Parker@SwissTech.ch

26 August 2013

Fax. No.

www.SwissTech-Automotive.ch

PAGE 1 / 1

7.2

19 | 5 2

Run @ Rate – (R@R) 8.1

Purpose The purpose of a Run @ Rate is to verify the supplier’s manufacturing process is capable of producing components that meet SwissTech’s quality requirements, at quoted tooling capacity, for a specified period of time. Verification of the Run @ Rate will be at the Supplier Quality Engineer’s (SQE) discretion. The supplier will be notified of the need to perform a Run @ Rate as early in the process as possible. The number of components to be produced during the Run @ Rate should be sufficient to demonstrate process capability and will be predetermined by the SQE and the supplier.

Note:

Factors such as product complexity, shelf life, storage, cost and single shift vs. multiple shift operations will be taken into consideration.

8.2

Scope All new parts require a Run @ Rate, unless exempted by the supplier quality engineer and approved by the Supplier Quality and Purchasing Directors of the procuring division.

8.3

Selection Process All new part numbers will be evaluated by SwissTech, taking into consideration factors such as the following: history; new technology; irreversible tooling changes; and new supplier facilities. The need for the Run @ Rate will be confirmed by the Supplier Quality Engineer, and approved by the Supplier Quality and Purchasing Director(s) of the procuring division. The supplier will be notified of the need to perform a customer monitored or supplier monitored Run @ Rate as early in the Advanced Product Quality Planning Process as possible. Note: See Section VIII for Additional Requirements for Supplier monitored Run @ Rate.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

20 | 5 2

Appendix 5. (SwissTech Run@Rate worksheet)

Run @ Rate Worksheet

DOC. CODE

REV.

QD-R@R-I

Part Number ____-__-___-__

TYPE of RUN@RATE PRODUCT INFORMATION Part Description

Air Brake Disc / Rotor

SwissTech Part 4DB.12B.4528-00 ℗ № Supplier Ref. № ABC-123

Drawing №

REPORTING INFORMATION

SwissTech +T DBR-4528 Smart № OE Ref. № 942 421 21 12

Performed By (Name) Supplier (Name)

Application

Facility Location

Zolikon

Verified By (SwissTech)

Jean Paul Schwartzenberg

MERCEDES-BENZ

Drawing Rev. Level

123456789Z

Inspection Date (Org.) Vendor No.

Jacque van Nassau Preud'homme d'Hailly de Nieuport

SUPPLIER DATA

Submission Date Review Date (SwissTech)

15 September 2013 101 30 September 2013 02 October 2013

SWISSTECH DATA

A. Quoted Tool Capacity (QTC) [QTY/YR]

Max Schedule Volume [QTY / YR]

500,000

B. Production Days [DAYS/YR]

Production Days [DAYS / YR]

330

C. Quoted Daily Capacity [QTY/DAY]

345,000 330

Daily Volume [QTY / DAY]

1,515

PLANNED MACHINE LOADING

1,045

SUPPLIER TOOLING INFORMATION

D. Total Shift Time [GROSS HRS / DAY]

1.5

E. Planned Allocation for this Part [ % ]

100%

F. Gross Hours / Day, for this Part [HRS / DAY]

1.5

RUN @ RATE DATA PLANNED

ACTUAL

G. Duration of RUN @ RATE [HRS]: H. Downtime During RUN @ RATE: 1. Breaks 2. Lunch 3. Maintenance 4. Changeover/Setup Time 5. Unplanned 6. Total [1 - 5] I. Net Productive Time J. Part Quantities Produced 1. Total Number of Parts [#]: 2. Total Rejected Parts [#]: 3. Net Good [#]: 4. Net Parts/Hour [# / HR]:

COMMENTS

MIN

HRS

MIN

HRS

0.42

0.50

0.75

0.25

0.17

1.00

0.00

0.50

2.17

2.92

6.83

6.08

5,500

5,234

5,473

4,951

801

814

TOOL CAPACITY / PRODUCTION LINE CAPACITY / SCHEDULE ACTUAL TC

QUOTED TC

MSV

K. Net Daily Capacity [QTY / DAY]

1,221

1,515

1,045

L. Net Annual Capacity [QTY / YR]

402,862

500,000

345,000

RUN @ RATE RESULTS ACTUAL TC > QTC and ACTUAL TC > MSV ACTUAL TC < QTC but ACTUAL TC > MSV

OPEN

ACTUAL TC > QTC but ACTUAL TC < MSV ACTUAL TC < QTC and ACTUAL TC < MSV CONCURRENCE Supplier Repr.

Name Pierre Flugi van Aspermont

Signature

Date

16/09/2013

SwissTech Repr.

Name Jean Paul Schwartzenberg

Signature

Date

20/09/2013

Document: QD-R@R-Rev.1.0

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

PAGE 1 / 1

8.4

21 | 5 2

Process Flow Diagram 9.1

What is a Process Flow Diagram? A visual diagram of the entire process from receiving through shipping, including outside processes and services

9.2

Objective and Purpose To help people “see” the real process. Process maps can be used to understand the following characteristics of a process:  Set-by-step process linkage  Offline activities (measurement, inspection, handling)  Rework, scrap

9.3

Applicability  To understand how a process is done  Prior to completing the PFMEA (Example Process Flow Diagram)

Operator Separate Cutting Tags (31)

Evaluate for Corrective Action

Yes Operator Get Traveler and Nest from Holding Shelf (26)

Operator Load Machine with Blanket (28)

Operator Prints Cut Tags (27)

Operator Download Cutting Infomation (2s to 2m) (29)

Operator Program Command "Ready to Cut" (30)

Operator Observe Cutting Operation for Errors (32)

Cutting Error? (33)

Operator Remove Small Plies from the Cutting Table (36)

Operator Move to Kitting Table (37)

Operator Tag Small Plies (38) No

Small Plies Operator Cutting Operation Complete (34)

Large or Small Plies or Test Coupons? (35)

Document: QD-PSRG-Rev.1.0

Operator Tag while Laying on the Cutting Table And (39) Coupons Large Piies

Operator Remove Plies from the Cutting Table (40)

Operator Move Plies to Kitting Table (41)

Traveler Complete? (42)

Yes

Operator Stamp Traveler (43)

www.SwissTech-Automotive.ch

22 | 5 2 Appendix 6. (SwissTech’s Process Diagram Template)

PROCESS FLOW DIAGRAM

DOC. CODE

REV.

QD-PFD-I

PART Number 4DB.12B.4528-00 ℗

PRODUCT INFORMATION Part Description

Air Brake Disc / Rotor

SwissTech Part 4DB.12B.4528-00 ℗ № SwissTech +T DBR-4528 Smart №

REPORTING INFORMATION

Supplier ABC-123 Ref. № OE Ref. № 942 421 21 12

Performed By [name]

Application

Drawing №

Supplier (Name)

MERCEDES-BENZ

Jacque van Nassau Preud'homme d'Hailly de Nieuport 123456789Z

Rev. Level

Issue 28 September 2013 Date Vendor 101 № Review 02 October 2013 Date

LEGEND (Utilizes these symbols to clearly identify each step in the process)

Step

Operations

Movement

Description of the process step

Inspection

Storage

Operation or Event [Utilize Symbols] In house

Begin / end of the process

Description of the Operation or Event

3rd Party

Duration of the Op./ Event

Evaluation and Analysis Methods

Arrival of base material

Begin of the process

0.00

Incoming Inspection

Take 10 samples of the material for layout inspection

25.00 Vickers, Brinell, Rockwell

Move to the warehouse

By Fork lift truck the material will be moved into the warehouse

3.00

Move mat. To operator

By Crane

2.10

Drilling Holes

Using GMC 20 Multi Spindle Lathe CNC equipment

0.12

Move to Hardening

By truck

17.00

Case Hardening Process

Describe detailed the (hardening) specifications

21.70

Move to final inspection area

By Crane

1.30

Dimensional Inspection

100% Dimensional Inspection by using fixture mold

18.00

10 Final Inspection

surface roughness measuring by 1 sample / batch of 100 pcs

12.00 Mitutoyo equipment

End of the process

0.00

FOR SWISSTECH USE ONLY Verified By (Name) Jean Paul Schwartzenberg Document: QD-PFD-Rev.1.0

Document: QD-PSRG-Rev.1.0

Insp. Date

02 October 2013

Signature

www.SwissTech-Automotive.ch

PAGE 1 / 1

9.4

23 | 5 2 10. Failure Mode and Effects Analysis (FMEA) FMEA was one of the first systematic techniques for failure analysis. It was developed by reliability engineers in the 1950s to study problems that might arise from malfunctions of military systems. A FMEA is often the first step of a system reliability study. It involves reviewing as many components, assemblies, and subsystems as possible to identify failure modes, and their causes and effects. For each component, the failure modes and their resulting effects on the rest of the system are recorded in a specific FMEA worksheet. There are numerous variations of such worksheets. A FMEA is mainly a qualitative Analysis. A few different types of FMEA analysis exist, like  Functional, (FFMEA)  Design, (DFMEA) and  Process FMEA (PFMEA) A successful FMEA activity helps to identify potential failure modes based on experience with similar products and processes - or based on common physics of failure logic. 10.1

Basic FMEA terminology  Failure The loss under stated conditions.  Failure mode The specific manner or way by which a failure occurs in terms of failure of the item (being a part or (sub) system) function under investigation; it may generally describe the way the failure occurs. It shall at least clearly describe a (end) failure state of the item (or function in case of a Functional FMEA) under consideration. It is the result of the failure mechanism (cause of the failure mode). For example; a fully fractured axle, a deformed axle or a fully open or fully closed electrical contact are each a separate failure mode.  Failure cause and/or mechanism Defects in requirements, design, process, quality control, handling or part application, which are the underlying cause or sequence of causes that initiate a process (mechanism) that leads to a failure mode over a certain time. A failure mode may have more causes. For example; "fatigue or corrosion of a structural beam" or "fretting corrosion in an electrical contact" is a failure mechanism and in itself (likely) not a failure mode. The related failure mode (end state) is a "full fracture of structural beam" or "an open electrical contact". The initial Cause might have been "Improper application of corrosion protection layer (paint)" and /or "(abnormal) vibration input from another (possible failed) system".  Failure effect Immediate consequences of a failure on operation, function or functionality, or status of some item.  Indenture levels (bill of material or functional breakdown) An identifier for system level and thereby item complexity. Complexity increases as levels are closer to one.  Local effect The failure effect as it applies to the item under analysis.  Next higher level effect The failure effect as it applies at the next higher indenture level.  End effect The failure effect at the highest indenture level or total system.  Detection The means of detection of the failure mode by maintainer, operator or built in detection system, including estimated dormancy period (if applicable)  Risk Priority Number (RPN) Cost (of the event) * Probability (of the event occurring) * Detection (Probability that the event would not be detected before the user was aware of it)  Severity The consequences of a failure mode. Severity considers the worst potential consequence of a failure, determined by the degree of injury, property damage, system damage and/or time lost to repair the failure.  Remarks / mitigation / actions Additional info, including the proposed mitigation or actions used to lower a risk or justify a risk level or scenario

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

24 | 5 2 Appendix 7. (Process FMEA Template)

PROCESS FAILURE MODE AND EFFECTS ANALYSIS

DOC. CODE

REV.

QD-P-FMEA-I

PFMEA Number

(PFMEA)

Facilitator

Patrick Dumonceau

Timekeeper Product Item / Type 4DB.12B.4528-00 ℗ Scribe №

FMEA Number

Core Team:

Paul Von Riedesel d'Eisenbach

Jacque van Nassau

Job T itle

Paul Von Riedesel d'Eisenbach Patrick Dumonceau Jacque van Nassau Pierre Flugi van Aspermont

Project Leader Performed By: Paul Von Riedesel d'Eisenbach QA Supervisor QA Mgr. FMEA Issue Date (Orig.) 28 September 2013 Lead Engineer Review Date 02 October 2013 (SwissTech)

Pierre Flugi van Aspermont

Current Prevention Controls

Current Detection Controls

Recommend Actions

S O D

RPN ( < 100)

Potential Causes of Failure

CHECK

RPN ( < 100)

Classification

Product Potential Potential function effect(s) of Failure mode description Failure

00246

Name

Responsibility & Target Completion Date

ACT

Action Results Actual Analysis & Effective date

S O D

RPN

PLAN

Project Leader

Potential Failure Mode and Effects Analysis

00246

Is the new RPN sufficient or is further activity required?

X Intended outcomes

X What can go wrong?

No Function Degraded Function over time intermittent Function.

X X

What is the consequence?

X How bad?

X What is the Cause?

X How often does it happen?

X X

How can this be Prevented & Detected?

What can be done? Design Changes, Process Changes, Special Controls, Changes to Standards and Procedures.

How will these recommended change affect: Severity, Occurrence and Detection Rankings and hence RPN? Who is responsible?.

How good X is this method at Detecting?

X X

What was Actually done?

What impact did these Actual changes have to Severity; Occurrence and Detection and hence RPN?

Based on the Impact the Actual changes had on Severity, Occurrence and Detection, what is the next step?

Is the new RPN sufficient, or is further activity required?

X X X X X X X X X X X X X X X X X X X Sub-Total RPN Document: QD-P-FMEA-Rev.1.0

Document: QD-PSRG-Rev.1.0

Sub-Total RPN

Total RPN

www.SwissTech-Automotive.ch

PAGE 1 / 1

10.2

25 | 5 2 Appendix 8. (SwissTech FMEA Rating)

Failure Mode and Effects Analysis (RATING)

DOC. CODE

REV.

QD-R-FMEA-I

PART NUMBER _____ ______ ______

Rating

Degree of Severity Safety or environmental impact is insignificant; customer will not notice any adverse effects

Degree of Severity Customer will not notice the adverse effect or it is insignificant

Safety or environmental impact is slight; customer will probably experience slight annoyance

Customer will probably experience slight annoyance

Probability of Occurence Frequentcy ( 1 in â&#x20AC;Ś ) Likelihood of occurrence is remote 1,000,000

Customer dissatisfaction due Occasional failures to reduced performance

Considerable safety and/or environmental Impact due to failure of components; customer is made uncomfortable

Customer is made Relatively moderate failure uncomfortable or their rate with supporting productivity is reduced by the documentation continued degradation of the effect

5,000

2,000

Considerable safety and/or Warranty repair, down time or Moderate failure rate without environmental Impact due significant manufacturing or supporting documentation to continued degredation of assembly complaint components; warranty repair, down time or significant manufacturing or assembly complaint High safety risk and/or severe environmental Impact without violating existing codes/standards; High degree of customer dissatisfaction; productivity impacted by high scrap or rework levels.

High degree of customer Relatively high failure rate with dissatisfaction due to supporting documentation component failure without complete loss of function. Productivity impacted by high scrap or rework levels.

High safety risk and/or severe environmental Impact violating existing codes/standards; very high degree of customer dissatisfaction

Very high degree of High failure rate without dissatisfaction due to the loss supporting documentation of function without a negative impact on safety or governmental regulations

Severe Safety impact with warning before failure or violation of safety codes/regulations; customer endangered

Customer endangered due to Failure is almost certain the adverse effect on safe based on specifications or system performance with significant DV testing warning before failure or violation of governmental regulations

Severe Safety impact without warning before failure or violation of safety codes/regulations; customer endangered

Customer endangered due to Assured of failure based on the adverse effect on safe specifications or significant system performance without DV testing warning before failure or violation of governmental regulations

Document: QD-PSRG-Rev.1.0

1.33

Low failure rate without supporting documentation

Safety and/or environmental impact affected due to continually poor system performance; customer dissatisfied

Document: QD-R-FMEA-Rev.1.0

> 1.67

Low failure rate with supporting documentation 20,000

Safety and/or Customer will experience environmental impact will annoyance due to the slight be affected due to the degradation of performance slight degradation of performance of components; customer will experience annoyance

Cpk

500

100

approx. 1.0

< 1.0

Ability to Detect Detection Certainty Sure that the potential failure will be found or prevented before 100% producing a safety risk

Almost certain that the potential failure will be found or prevented before producing a safety risk Low likelihood that the potential failure will be prevented before producing a safety risk

Controls may detect or prevent the potential failure from occuring during operation

Moderate likelihood that the potential failure will occur before producing a safety risk

Controls are unlikely to detect or prevent the potential failure during operation

Poor likelihood that the potential failure will be detected or prevented before producing a safety risk Very poor likelihood that the potential failure will be detected or prevented before producing a safety risk Current controls probably will not even detect the potential failure

Absolute certainty that the current controls will not detect the potential failure

99%

< 50

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PAGE 1 / 1

10.3

26 | 5 2

Product function description

Potential Failure mode

Potential effect(s) of Failure

Potential Causes of Failure

Current Prevention Controls

Current Detection Controls

RPN

Step 1. Using the completed Process Flow Diagram, enter the process step.

PFMEA Process Steps Classification

10.4

Failure Modes For each Process Input, determine the ways in which the input can go wrong.

Potential Failure mode

Step 3. Potential Causes For each Failure Mode, determine the possible cause of the failure.

Potential effect(s) of Failure

Potential Causes of Failure

Current Prevention Controls

Current Detection Controls

RPN

Product function description

Classification

Step 2. Potential Failure Effects For each Failure Mode, determine what effect the specific failure could have on the process output.

Step 4. Current Controls For each potential cause, list the current method used for preventing or detecting failure.

Assign Occurrence (How likely is the cause to occur?) Step 5. Assign Severity (How serious is the effect if it fails?)

Document: QD-PSRG-Rev.1.0

Assign Detection (How easily can the cause or failure mode be detected?)

www.SwissTech-Automotive.ch

27 | 5 2

Rating High 10

Low 1

Severity

Occurrence

Detection* Cannot detect or Hazardous Very high and detection with without almost very low warning inevitable probability Loss of Remote or low High repeated primary chance of failures function detection Loss of Moderate Low detection secondary failures probability function Moderate Minor Occasional detection defect failures probability Failure Almost certain No effect unlikely detection *If No Controls Exist, Detection = 10

Step 6. Calculate the Risk Priority Number RPN = Severity x Occurrence x Detection

TIPS   

The RPN is used to prioritize the most critical risks identified in the first half of the FMEA. High RPNs (125 or above) are flags to take effort to reduce the calculated risk. Regardless of RPN, high Severity scores (9 or 10) should be given special attention.

Potential effect(s) of Failure

Potential Causes of Failure

Current Prevention Controls

Current Detection Controls

RPN

Potential Failure mode

Classification

Determine Actions Recommended to reduce High RPNs Recommend Actions

Step 7. For the high RPN numbers, determine the recommended actions.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

Recommend Actions

S O D

Responsibility Action Results & Target Completion Actual Analysis Date & Effective date S O

Actions Taken As actions are identified and analyzed, document in the “Actual Analysis” column.

RPN

Current Detection Controls

RPN

Current Prevention Controls

RPN

28 | 5 2

Step 8. Assign a specific person who will be responsible for recommended actions.

 TIPS: 

SEV, OCC, DET,RPN As actions are complete reassess Severity, Occurrence, and Detection and recalculate RPN.

Now recalculate your RPNs based on mitigation plans.

Continue updating the actions taken and resulting RPNs until all risks are at an acceptable level (below 125).

Analyzing the PFMEA

Product function description

Potential Failure mode

Potential effect(s) of Failure

Potential Causes of Failure

Current Prevention Controls

Current Detection Controls

Recommend Actions

S O D

RPN

10.6

RPN

Summary Steps To Complete a FMEA 1) For each Process Input, determine the ways in which the Process Step can go wrong (these are Failure Modes). 2) For each Failure Mode associated with the inputs, determine Effects on the outputs. 3) Identify potential Causes of each Failure Mode. 4) List the Current Controls for each Cause. 5) Assign Severity, Occurrence and Detection ratings after creating a ratings key appropriate for your project. 6) Calculate RPN. 7) Determine Recommended Actions to reduce High RPNs. 8) Take appropriate Actions and Document. 9) Recalculate RPNs. 10) Revisit steps 7 and 8 until all the significant RPNs have been addressed.

Classification

10.5

Intended outcomes

Sort by RPN to determine the most significant failure modes

What can go wrong? No Function Degraded Function over time intermittent Function.

What is the consequence?

What can be done? Design Changes, Process Changes, Special Controls, Changes to Standards and Procedures.

How bad? What is the Cause? How often does it happen? How can this

Document: QD-PSRG-Rev.1.0

How will these recommended change affect: Severity, Occurrence and Detection Rankings

www.SwissTech-Automotive.ch

29 | 5 2

RPN Thresholds  When using an RPN threshold, DO NOT forget to address high Severity scores  Once the RPN Numbers are determined, they can be used to prioritize the most significant failure modes.  Sort the FMEA by the RPN numbers. Graphical and statistical tools can help the team select a “cutoff” RPN for the next steps

10.7

PFMEA – Remediation Guidelines  Severity – can only be improved by a design change to the product or process  Occurrence – can only be reduced by a change which removes or controls a cause. Examples are redundancy, substituting a more reliable component or function or mistake-proofing.  Detection – can be reduced by improving detection. Examples are mistake-proofing, simplification and statistically sound monitoring. In general, reducing the Occurrence is preferable to improving the Detection

10.8

FMEA Checklist  Verify there is a system for prioritizing risk of failure such as RPN numbers of 125 or above  Make sure that high RPN process concerns are carried over into the control plan  Make sure that all critical failure modes are addressed  Safety  Form, fit, function  Material concerns

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

30 | 5 2

10.9

Process Flow Chart FMEA

11. Control Plan 11.1

What is a Control Plan A document that describes how to control the critical inputs to continue to meet customer expectations of the output.

Note: Since processes are expected to be continuously updated and improved, the control plan is a living document! 11.2

Objective or Purpose Primary reference source for minimizing process and product variation. Description of how teams should react to out-of-control situations.

11.3

Applicability Implementation of new process Following a process change

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

Prototype

Document: QD-PSRG-Rev.1.0 Production Key Contact

Business Phone №

Document: QD-CPLAN-Rev.1.0

Define part / process number.

Part / Process №

Define part/process operation and description.

Process Name / Operation Description

Define the characteristics of the product or process.

Process

Characteristics

Product

Li s t the ma chine, devi ce, jig, or tools that will be used i n the ma nufacturing process.

№

Characteristics

Machine/Tools

Machine Device, Tool used for Mfg.

Define the Sa fety cri tical a nd special cha rateristics of te product or process.

Submission Date

Use this area to define upper/lower spec limits for each control element.

For each line in the control plan, list the measurement procedure that will be used (may list R&R Gage Plan or Poka-Yoke).

Measurement Technique

Evaluation Measurement Technique

Sample

What is the size of the sample you should gather data from?

Sample Size

Size

PAGE 1 / 1

Actions to be taken if controls fail. .

Rection Plan

Reaction Plan

Method that will be used to control the process.

Control Method

Define the frequency for which the measurement will be taken.

Frequency

Date (If Required)

Other Approval Methods

Date (If Required)

02 October 2013

Date (Revision)

Customer Quality Approval

30 September 2013

Date (If Required)

Performance Date (Original)

____-__-___-__

Customer Engineering Approval

Specifications / Tolerance

Product / Process Specification Tolerance

Special Characteristics

Spec Characteristic Class

3 Distinct Phases 3. Production – a 2. Pre-Launch – a Jacque van Nassau +41 76 6789 001 1. Prototype – a comprehensive description of the description of the documentation of dimensional Part № Drawing № Latest Rev. Level Core Team dimensional product/process measurements and 4DB.12B.4528-00 ℗ 123456789Z B measurements and characteristics, process material and Part Description / Product Namematerial and SOP Date Part Approval Date controls, tests, and performance tests that performance tests measurement systems will occur after Prototype Air Brake Disc / Rotor 01 December 2013 30 September 2014 that will occur that will occur during and before full Supplier / Plant № Other Approval Date (If Required) during . massSupplier production Production. Location Preud'homme d'Hailly de Nieuport Zolikon 101

Pre-Launch

Control-Plan No.

11.4

Control Plan №

CONTROL PLAN

REV.

DOC. CODE QD-CPLAN-I

31 | 5 2

Appendix 9. (SwissTech Control Plan)

www.SwissTech-Automotive.ch

32 | 5 2

11.5

Audit Plans  Audit plans should be included in the control plan as a separate line.  Auditing is an important tool for control.  Process auditing should be a key element of the quality system of a business.  Audits generally cover:  Effectiveness of controls  Control plan (say) vs. what is actually done (do)  Audits should be objective (done by internal or external third parties if possible).  Audit frequencies should be based on balancing level of risk (FMEA) and cost.

12. Measurement Analysis System (MSA) 12.1

What is It? An MSA is a statistical tool used to determine if a measurement system is capable of precise measurement.

12.2

Objective or Purpose To determine how much error is in the measurement due to the measurement process itself. Quantifies the variability added by the measurement system. Applicable to attribute data and variable data.

12.3

When to Use It On the critical inputs and outputs prior to collecting data for analysis. For any new or modified process in order to ensure the quality of the data.

12.4

Who Should be Involved Everyone that measures and makes decisions about these measurements should be involved in the MSA.

Important: Measurement System Analysis is an analysis of the measurement process, not an analysis of the people!

Example of a MSA Chart

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

33 | 5 2

12.5

Attribute and Variable MSA Attribute Data Examples:  Count, Pass/fail, yes/no, red/green/yellow, timekeeping buckets Variable Data Examples:  Physical measurement (length, width, area, …)  Physical conditions (temperature, pressure…)  Physical properties (strength, load, strain…)  Continuous or non-ending Unless approved by an SwissTech SQE, attribute data is not acceptable for PPAP submission The observed variation in process output measurements is not simply the variation in the process itself; it is the variation in the process plus the variation in measurement that results from an inadequate measurement system.

Conducting an MSA reduces the likelihood of passing a bad part or rejecting a good part

12.6

Observed Variation

The output of the process measured by:  Cycle time  Dimensional data  Number of defects and others

Calibration addresses accuracy

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

34 | 5 2

12.7

Resolution Error in resolution. The inability to detect small changes. Possible Cause Wrong measurement device selected - divisions on scale not fine enough to detect changes.

12.8

Repeatability  Error in Repeatability The inability to get the same answer from repeated measurements made of the same item under absolutely identical conditions.  Possible Cause  Lack of standard operating procedures (SOP), lack of training, measuring system variability.

12.9

Reproducibility  Error in Reproducibility The inability to get the same answer from repeated measurements made under various conditions from different inspectors.  Possible Cause Lack of SOP, lack of training.

12.10

Variable MSA – Gage R&R Study Variable MSA – (Gage R&R Study)  Gage R&R is the combined estimate of measurement system Repeatability and Reproducibility  Typically, a 3-person study is performed  Each person randomly measures 10 marked parts per trial  Each person can perform up to 3 trials  There are 3 key indicators  EV or Equipment Variation  AV or Appraiser Variation  Overall % GRR

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

35 | 5 2

Appendix 10. MSA Gage Repeatability and Reproducibility (MSA GR&R)

MSA GAGE REPEATABILITY & REPRODUCIBILITY

DOC. CODE

REV.

QD-MSA-I

Gage Number ____-__-___-__

PRODUCT INFORMATION Part Description SwisTech Part № (Key) Drawing № Supplier [name]

GAGE INFORMATION Performed By [name]

Air Brake Disc / Rotor

Inspection Date

Gage Name

4DB.12B.4528-00 ℗

Drawing Revision Level

123456789Z

Preud'homme d'Hailly de Nieuport

Gage №

Characteristics

Gage Type

Process

Gage UOM

Gage Repeatability and Reproducibility Data Collection Section Operator 1 [name] 1

Nominal

Operator 2 [name]

John

1 [ + Pos. ] Tolerance

UOM

2.85622

3 Operator 3 [name]

Mark [ - Neg. ]Tolerance

1 No. Of Trials >1 [ n value ]

Paul Samples size >1 [ m value ]

1.41102

SwissTech Gage Repeatability and Reproducibility Criteria Cp [σ Sigma] > 2 [σ Sigma] Cpk [σ Sigma] >1.33 5.15

2.13

1.41

Sample size Observations Trial no. 1 2 Operator 1

John

Average

28.129

22.688

27.539

27.688

26.490

29.414

28.244

24.311

25.055

26.30

24.315

26.377

26.320

29.744

22.398

24.588

29.296

22.988

25.174

27.417

27.094

29.730

27.103

25.147

22.724

26.03

23.970

27.508

25.257

29.551

23.053

26.386

28.859

22.909

25.098

26.363

25.657

29.771

28.759

24.297

25.852

26.22

24.200

26.630

25.400

29.400

22.420

25.820

28.910

22.135

26.287

26.982

25.761

29.400

25.590

25.400

23.476

25.85

24.600

26.810

26.100

29.600

22.580

26.120

28.526

22.877

25.197

27.133

26.630

29.744

25.820

26.320

22.420

26.03

Average

24.47

26.91

25.61

29.49

22.62

25.72

28.74

22.72

25.86

27.12

26.33

29.61

27.10

25.09

23.91

X-bara

26.09

Range

1.32

1.13

1.33

0.57

0.66

1.80

1.17

0.85

2.44

1.33

1.44

0.37

3.17

2.02

3.43

R-Bara

1.53

Average

24.279

26.486

24.311

29.414

22.479

24.974

28.555

22.963

26.162

26.958

27.221

31.759

25.674

25.230

22.479

25.93

24.654

26.158

25.147

29.730

23.553

25.137

27.526

21.180

25.662

26.638

26.377

29.350

24.588

25.184

23.553

25.63

24.682

25.761

24.297

29.771

23.476

25.590

28.972

21.332

26.570

26.797

27.508

28.438

26.386

24.155

23.476

25.81

24.769

26.413

25.400

29.400

22.420

25.820

28.910

22.135

26.287

26.982

26.630

29.771

25.820

24.297

22.420

25.83

24.315

26.377

26.320

29.744

22.398

24.588

29.296

22.988

25.174

27.417

26.810

29.400

26.120

25.400

22.398

Average

24.54

26.24

25.09

29.61

22.86

25.22

28.65

22.12

25.97

26.96

26.91

29.74

25.72

24.85

22.86

X-barb

25.82

Range

0.49

0.72

2.02

0.37

1.15

1.23

1.77

1.81

1.40

0.78

1.13

3.32

1.80

1.24

1.15

R-Barb

1.36

25.92

Average

25.559

26.490

25.230

31.759

25.055

28.244

30.126

23.513

27.141

28.033

26.486

29.169

24.974

24.993

22.639

26.63

24.504

27.094

25.184

29.350

22.724

27.103

27.505

22.802

25.379

26.918

26.158

29.744

25.137

26.320

22.398

25.89

27.738

25.657

24.155

28.438

25.852

28.759

30.000

24.049

27.255

29.094

25.761

29.551

25.590

25.257

23.053

26.68

24.682

25.761

24.297

29.771

23.476

25.590

28.972

21.332

26.570

26.797

26.413

29.400

25.820

25.400

22.420

25.78

24.200

26.630

25.400

29.400

22.420

25.820

28.910

22.135

26.287

26.982

26.377

29.600

24.588

26.100

22.580

Average

25.34

26.33

24.85

29.74

23.91

27.10

29.10

22.77

26.53

27.56

26.24

29.49

25.22

25.61

22.62

X-barc

Range

3.54

1.44

1.24

3.32

3.43

3.17

2.62

2.72

1.88

2.30

0.72

0.57

1.23

1.33

0.66

R-Barc

2.01

X-barp

26.02

R-barp

7.08

24.78

26.49

25.19

29.62

23.13

26.01

28.83

22.53

26.12

27.21

26.49

29.62

26.01

25.19

23.13

1.78

1.10

1.53

1.42

1.75

2.07

1.85

1.79

1.90

1.47

1.10

1.42

2.07

1.53

1.75

Key Values

Gage Repeatability and Reproducibility Tolerance & % Variation Study Summery Report Equipment Variation Appraiser Variation Gage R&R Part Variation [ PV ] Tot. Variation [ TV ]

0.5230

d*2

3.4880

x̅diff

0.3368

0.2815

d2 d3

2.6921

R-barp

7.0812

25.674

0.4299

Rejected

22.639

Final Result

29.169

0.5770

Yes

24.993

Calculation Values

Is the part Stable?

27.221

Part Average

25.285

Sample size Observations Trial no. 1 2 Operator 3

Paul

ndc >

Sample size Observations Trial no. 1 2 Operator 2

Mark

GR&R up to 20.00% [Marginal]

GR&R < [Pass] 10.00%

1/d2

1.4270

0.0000

2.0890

2.3260

0.2880 0.8640 0.0000 2.1140

̿x

R̅ Max Range Min Range Total Tolerance

26.024

1.6352

EV % EV % EV -TV

9.000

7.81% 33.16%

% AV % AV -TV

0.17 1.84% 7.79%

Equipment Variation Appraiser Variation

[ EV σ ₓ ]

3.5377 σrepeatabi 0.3714

0.70

lity

% σEV

[ AV σ ₓ ]

0.14

σreproduci

1.52%

% σAV

bility

% σEV -TV 33.16% % σAV -TV

GR&R % GR&R % GR&R TV

Document: QD-PSRG-Rev.1.0

8.02% 34.07%

Gage R&R [ GR&R σ ₓ ]

% PV % PV - TV

1.99 94.02% 94.02%

TV ndc ≈ Min % GR&R

2.12 3.9 8.0%

USL USL

σGR&R

0.36%

% σGR&R

0.14

σPV

1.56%

% σPV

7.79%

% σGR&R- 34.07% % σPV -TV 94.02%

0.39 4.30%

σTV ndc ≈ σMin %

26.16

LSL

29.00

x̅ Bar Chart StdDev

Part Variation [ PV ] Tot. Variation [ TV ] CL [ ̿x ] [ PV σ ₓ ] [ PV σ ₓ ]

0.03

TV Document: QD-MSA-Rev.1.0

0.72

25.83

LSL

20.00

R̅ Bar Chart

0.70

StdDev

0.70

26.02

CL [ ̿x ]

1.73

0.41

UCL_xA2

30.11

UCL_rD4

3.46

3.9

LCL_xA2

21.94

LCL_rD3

0.00

1.6%

www.SwissTech-Automotive.ch

PAGE 1 / 1

12.11

Document: QD-PSRG-Rev.1.0

2 26.91 26.24 26.33 26.49 7.08 1.13 0.72 1.44 0.34 1.64 26.02 3.54 0.37 0.71 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

5 2.4810 2.4050 2.3790 2.3660 2.3580 2.3530 2.3490 2.3460 2.3440 2.3420 2.3400 2.3439 2.3380 2.3370 2.3370

d*2

4 29.49 29.61 29.74 29.62 7.08 0.57 0.37 3.32 0.34 1.64 26.02 3.54 0.37 2.95 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

7 2.8300 2.7680 2.7470 2.7360 2.7300 2.7260 2.7230 2.7200 2.7190 2.7170 2.7160 2.7150 2.7140 2.7140 2.7130

Situation

3 25.61 25.09 24.85 25.19 7.08 1.33 2.02 1.24 0.34 1.64 26.02 3.54 0.37 0.78 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

6 2.6730 2.6040 2.5810 2.5700 2.5630 2.5580 2.5550 2.5520 2.5500 2.5490 2.5470 2.5460 2.5450 2.5450 2.5440

www.SwissTech-Automotive.ch

Document: QD-MSA-DAT A-Rev.1.0

10 27.12 26.96 27.56 27.21 7.08 1.33 0.78 2.30 0.34 1.64 26.02 3.54 0.37 1.52 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

13 3.4240 3.3800 3.3660 3.3580 3.3540 3.3510 3.3490 3.3470 3.3460 3.3450 3.3440 3.3430 3.3430 3.3420 3.3420 11 26.33 26.91 26.24 26.49 7.08 1.44 1.13 0.72 0.34 1.64 26.02 3.54 0.37 0.71 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

14 3.4910 3.4490 3.4350 3.4280 3.4240 3.4210 3.4190 3.4170 3.4160 3.4150 3.4150 3.4140 3.4130 3.4130 3.4120 12 29.61 29.74 29.49 29.62 7.08 0.37 3.32 0.57 0.34 1.64 26.02 3.54 0.37 2.95 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

15 3.5530 3.5130 3.4990 3.4920 3.4880 3.4860 3.4840 3.4820 3.4810 3.4800 3.4790 3.4790 3.4780 3.4780 3.4770 13 27.10 25.72 25.22 26.01 7.08 3.17 1.80 1.23 0.34 1.64 26.02 3.54 0.37 1.94 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

14 25.09 24.85 25.61 25.19 7.08 2.02 1.24 1.33 0.34 1.64 26.02 3.54 0.37 0.78 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

X̅ Chart LCL LCL A2 A3 * * 1.8800 2.6590 1.0230 1.9540 0.7290 1.6280 0.5770 1.4270 0.4830 1.2870 0.4190 1.1820 0.3730 1.0990 0.3370 1.0320 0.3080 0.9750 0.2850 0.9270 0.2660 0.8860 0.2490 0.8500 0.2350 0.8170 0.2230 0.7890 15 23.91 22.86 22.62 23.13 7.08 3.43 1.15 0.66 0.34 1.64 26.02 3.54 0.37 2.78 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

S Chart LCL LCL B3 B4 * * 0.0000 3.2670 0.0000 2.5680 0.0000 2.2660 0.0000 2.0890 0.0300 1.9700 0.1180 1.8820 0.1850 1.8150 0.2390 1.7610 0.2840 1.7160 0.3210 1.6790 0.3540 1.6460 0.3820 1.6180 0.4060 1.5940 0.4280 1.5720

1.33 1.5 1.5 1.67 2

1.25 1.45 1.45 1.6 2

Recommended minimum process capability for Recommended minimum process two-sided specifications capability for one-sided specification

9 25.86 25.97 26.53 26.12 7.08 2.44 1.40 1.88 0.34 1.64 26.02 3.54 0.37 1.04 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

Test Performance Results 5 6 7 8 22.62 25.72 28.74 22.72 22.86 25.22 28.65 22.12 23.91 27.10 29.10 22.77 23.13 26.01 28.83 22.53 7.08 7.08 7.08 7.08 0.66 1.80 1.17 0.85 1.15 1.23 1.77 1.81 3.43 3.17 2.62 2.72 0.34 0.34 0.34 0.34 1.64 1.64 1.64 1.64 26.02 26.02 26.02 26.02 3.54 3.54 3.54 3.54 0.37 0.37 0.37 0.37 2.78 1.94 1.45 1.86 29.00 29.00 29.00 29.00 20.00 20.00 20.00 20.00 9.00 9.00 9.00 9.00 0.70 0.70 0.70 0.70 26.02 26.02 26.02 26.02 30.11 30.11 30.11 30.11 21.94 21.94 21.94 21.94 0.70 0.70 0.70 0.70 1.73 1.73 1.73 1.73 3.46 3.46 3.46 3.46 0.00 0.00 0.00 0.00

10 3.1790 3.1290 3.1120 3.1030 3.0980 3.0950 3.0920 3.0900 3.0890 3.0880 3.0870 3.0860 3.0850 3.0850 3.0840

12 3.3500 3.3050 3.2890 3.2820 3.2770 3.2740 3.2720 3.2700 3.2690 3.2680 3.2670 3.2660 3.2660 3.2650 3.2650

9 3.0780 3.0250 3.0060 2.9970 2.9920 2.9880 2.9860 2.9840 2.9820 2.9810 2.9800 2.9790 2.9780 2.9780 2.9770

CONSTANTS 11 3.2690 3.2210 3.2050 3.1970 3.1920 3.1890 3.1870 3.1850 3.1840 3.1830 3.1820 3.1810 3.1800 3.1800 3.1790

8 2.9630 2.9060 2.8860 2.8770 2.8710 2.8670 2.8640 2.8620 2.8600 2.8590 2.8580 2.8570 2.8560 2.8560 2.8550

Existing process New process Safety or critical parameter for existing process Safety or critical parameter for new process Six Sigma quality process

1 24.47 24.54 25.34 24.78 7.08 1.32 0.49 3.54 0.34 1.64 26.02 3.54 0.37 3.05 29.00 20.00 9.00 0.70 26.02 30.11 21.94 0.70 1.73 3.46 0.00

Part Sample Number 26.087 John 25.824 Mark 26.161 Paul 26.024 Xbarp 7.081 Rbarp 1.535 John 1.360 Mark 2.011 Paul 0.337 xd ̅ iff 1.635 R̅ 26.024 ̿x 3.538 Max Range 0.371 Min Range 1.816 R= High-Low 29.000 USL 20.000 LSL 9.000 Tot. Tolorance StdDev 0.703 CL 26.02 30.11 UCL_xA2 21.94 LCL_xA2 StdDev 0.703 CL 1.73 3.46 UCL_rD4 0.00 LCL_rD3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

4 2.2390 2.1510 2.1200 2.1050 2.0960 2.0900 2.0850 2.0820 2.0800 2.0770 2.0760 2.0740 2.0730 2.0720 2.0710

2 1.4140 1.2790 1.2310 1.2060 1.1910 1.1810 1.1730 1.1680 1.1640 1.1600 1.1570 1.1550 1.1530 1.1510 1.1500

Samples size [ m ]

3 1.9120 1.8050 1.7690 1.7500 1.7390 1.7310 1.7260 1.7210 1.7180 1.7160 1.7140 1.7120 1.7100 1.7090 1.7080

Observation Group Size [ n] d2

0.8200 0.8530 0.8880 0.8800 0.8640 0.8480 0.8330 0.8200 0.8080 0.7970 0.7870 0.7780 0.7700 0.7620 0.7550

* 0.8865 0.5907 0.4857 0.4299 0.3946 0.3698 0.3512 0.3367 0.3249 0.3152 0.3069 0.2998 0.2935 0.2880

TRIALS

Defective Parts

R Chart LCL LCL D3 D4 * * 0.0000 3.2670 0.0000 2.5740 0.0000 2.2820 0.0000 2.1140 0.0000 2.0040 0.0760 1.9240 0.1360 1.8640 0.1840 1.8160 0.2230 1.7770 0.2560 1.7440 0.2830 1.7170 0.3070 1.6930 0.3280 1.6720 0.3470 1.6530 * 0.7072 0.5230 0.4466 0.4031 0.3741 0.3534 0.3375 0.3249 0.3146 0.3059 0.2985 0.2921 0.2865 0.2815

PARTS

Fraction Defective

* 0.7072 0.5230 0.4466 0.4031 0.3741 0.3534 0.3375 0.3249 0.3146 0.3059 0.2985 0.2921 0.2865 0.2815

APPRAISERS

p̅ Chart

p̅

Total number of defects from all samples Number of samples × Sample size

Cpk = whichever is the smallest no.

317 per thousand 0.3173 45 per thousand 0.0455 2.7 per thousand 0.0027 63 per million 0.000063 574 per billion 0.000000574 2 per billion 0.000000002 Definitions n = Total number of observations m = Total number of samples r = Total number of trails xᵢ̅ = Observed value x̅ = Mean of the Sample x̿ = The average of the means of the samples j = Sample number Rj = Difference between the highest and lowest measurement in the sample R̅ = Average of the measurement differences R for all samples Formula's UCL [ Upper control limit ] for x̅ Chart x̅ = ̿x + A₂*R LCL [ Lower control limit ] for x̅ Chart x̅ = ̿x - A₂*R Upper control limit for R̅ Chart R = D₄*R̅ Lower control limit for R̅ Chart R = D₃*R̅ Mid / Center point x̅ Bar Chart (UCL_rA₂ + LCL_rA₂) / 2 R̅ Standard Deviation [ Sigma σₓ ] σₓ = d₂ Overall mean ∑ ͫᵢ = 1 xᵢ̅ ̿x = m (The overall estimate of the process) USL - LSL Process Capability Cp = 6 * σₓ (R bar / d₂) ̿x - LSL or USL - ̿x Process Capability Cpk = Min 3 *σ 3 *σ

±1σ [ sigma ] ±2σ [ sigma ] ±3σ [ sigma ] ±4σ [ sigma ] ±5σ [ sigma ] ±6σ [ sigma ]

Design Limits

1.0000 1.1280 1.6930 2.0590 2.3260 2.5340 2.7040 2.8470 2.9700 3.0780 3.1730 3.2580 3.3360 3.4070 3.4720

d3/d2 0.8200 0.7562 0.5245 0.4274 0.3715 0.3346 0.3081 0.2880 0.2721 0.2589 0.2480 0.2388 0.2308 0.2237 0.2175

for Sigma Estimate

12.12

x̅ Bar Chart x̅ Bar Chart

MSA GAGE REPEATABILITY & REPRODUCIBILITY DATA TABLE

36 | 5 2

Appendix 11. (MSA GR&R DATA TABLE)

PAGE 1 / 1

Document: QD-PSRG-Rev.1.0

UCL_xA2

Document: QD-GageR&R (GC)-Rev.1.0

20.00

22.00

24.00

26.00

28.00

30.00

LCL_xA2

̿x

Xbarp

x ̅ bar Average f o r a l l o p er a tor s 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00

20.00

32.00

22.00

̿x

24.00

LCL_xA2

26.00

UCL_xA2

28.00

32.00 30.00

R̅

4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00

28.00

John

LCL_rD3

P a r t A p p ra iser A ver a ge C h a rt

UCL_rD4

R ep ea t a b ili ty C o nt rol C h a rt

StdDev

Operat or ₁

John

Operat or ₁

Sample size 15

INDEX INFORMATION No. Of Trials >1 No. of appraisers

Upper Spec. Limit Lower Spec. Limit Total Tolerance 9

StdDev

LCL_xA2

̿x

UCL_rD4

LCL_rD3

R̅

R-barp

A ver a g e f o r a l l o p era tors

UCL_xA2

R ̅ bar Range

Mark

LCL_rD3

P a r t A p pra iser A vera ge C h a r t

UCL_rD4

R ep ea t ab ili ty C o n tro l C h a rt

StdDev

Operat or ₂

Mark

Operat or ₂

GAGE REPEATABILITY & REPRODUCIBILITY GRAPHIC CHARTS

30.00

32.00

4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00

Gage UOM

Gage Type

Gage Number

Inspec. Date

34 30 26 22 18 14 10 6 2 -2

20.00

22.00

24.00

26.00

28.00

30.00

32.00

4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00

Paul

UCL_rD4

LCL_rD3

UCL_xA2

LCL_xA2

̿x

R̅

3.54

0.37

3.89

2.12

T o t a l Va r i ati on b y P a r t N u mber

Paul

Min Range

Max Range

[ TV ] Total Variation ndc ≈

P a r t A p pra iser A vera ge C h a r t

StdDev

38.7%

34.1%

7.8%

33.2%

R ep ea t ab ili ty C o n tro l C h a rt

38.7%

34.1%

1.8%

7.8%

Operat or ₃

0.94

0.72

0.02

0.70

Operat or ₃

σPV / [%]

σGR&R / [%]

σAV / [%]

σEV / [%] EV-TV

Appendix for GR&R. No.

12.13

Special Characteristics Process

Performed By (Name) Gage Name

GR&R GRAPHIC OVERVIEW

REV.

DOC. CODE QD-GR&R (GC)

37 | 5 2

Appendix 12. (MSA GR&R GRAPICS)

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PAGE 1 / 1

38 | 5 2

12.14

Variable MSA – (Gage R&R Steps) 1. Select 10 items that represent the full range of long-term process variation. 2. Identify the appraisers.  Should use individuals that actually do the process being tested.  Can also include other appraisers (supervisors, etc.).  Should have a minimum of 3 appraisers. 3. If appropriate, calibrate the gage or verify that the last calibration date is valid. 4. Open the Gage R&R worksheet in the PPAP Workbook to record data. 5. Have each appraiser (operator) assess each part 3 times (trials – first in order, second in reverse order, third random).  Each appraiser has to work independently.  Items should be evaluated in random order.  After each appraiser completes the first evaluation of all items – repeat the process at least 2 more times.  Do not let the appraisers see any of the data during the test !! 6. Input data into the Gage R&R worksheet. 7. Enter the number of operators, trials, samples and specification limits 8. Analyze data in the Gage R&R worksheet. 9. Assess MSA Trust Level. – – –

Red: > 20% (rejected) Yellow: 10-20% (marginal) Green: < 10% (pass)

10. Take actions for improvement if necessary.  Brainstorm with the team for improvement solutions.  Determine best “practical solution” (may require some experimentation).  Pilot the best solution (PDSA)  Implement best solution – train employees.  Re-run the study to verify the improvement. 12.15

Problem Statement The sulfuric acid concentration in process tank 8 is measured at least once per day Additions/deletions of chemicals and decisions to shut down the process are dependent on these results. Based on current data, we need to do an MSA.

12.16

MSA Process A Gage Repeatability and Reproducibility was conducted in order to validate the process.

12.17

MSA Parameters  (3) Operators  (3) Trials  (10) Samples

12.18

Inspection Instructions 1. All inspectors need to wait outside the room when it is not their turn to evaluate the stars. 2. Open the PPAP Training Templates.xls file, then select the Gage R&R worksheet to record the data. 3. Round 1. Have the 1st inspector come in the room and measure all 10 stars in order. Data collector record the data in the Gage R&R worksheet. >> Do not give any additional information to the inspector << 4. Repeat Step 3 with the 2nd inspector 5. Repeat Step 3 with the 3rd inspector 6. Round 2. Change the inspection to reverse order and repeat. 7. Round 3. Change the inspection to random order and repeat.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

39 | 5 2

12.19

Gage R&R Exercise – (Analysis Instructions) 1. Complete the top section of the Gage R&R worksheet  Enter the number of operators, trials, and samples  Enter the upper and lower specification limit 2. Assess MSA Trust Level.  Red: > 20% (fail)  Yellow: 10-20% (marginal)  Green: < 10% (pass) 3. Interpret results - are improvements required?

12.20

Tips and Lessons Learned  Important: An MSA is an analysis of the process, not an analysis of the people. If an MSA fails, the process failed.  A Variable MSA provides more analysis capability than an Attribute MSA. For this and other reasons, always use variable data if possible.  The involvement of people is the key to success.  Involve the people that actually work the process  Involve the supervision  Involve the suppliers and customers of the process  An MSA primarily addresses precision with limited accuracy information.

12.21

Checklist  If the gage/inspection affects quality, then conduct a Gage R&R  Make sure the study is recent - less than 1 year  Compare the control plan gages against the Gage R&Rs  If you question that gage, then  Question the technique and part sampling

13. Dimensional Results 13.1

What is it? Evidence that dimensional verifications have been completed and results indicate compliance with specified requirements.

13.2

Objective and Purpose To show conformance to the customer part print on dimensions and all other noted requirements.

13.3

Applicability For each unique manufacturing process (e.g., cells or production lines and all molds, patters, or dies.

13.4

Check List  Thirty-five critical data points & 5 non-critical data points are required for part qualification.  Critical and non-critical data points must be taken from the same 35-piece sample.  Five parts from a production run must be shipped to SwissTech for verification of form, fit, and function.  The same 5 parts will be used to verify both critical and non-critical dimensions.  Supplier must clearly identify which of the 35 parts are being shipped.  Supplier should make every effort to ship 5 parts that represent both the low and high ends of the specifications for non-critical dimensions.  Capability must be greater than 1.67 for critical dimensions and greater than 1.33 for non-critical dimensions.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

40 | 5 2 Appendix 13. First Article Inspection Report (FAIR)

FIRST ARTICLE INSPECTION REPORT

DOC. CODE

REV.

QD-FAIR-I

PART Number 4DB.12B.4528-00 ℗

PRODUCT INFORMATION

Part №

4DB.12B.4528-00 ℗

SwissTech Part №

4DB.12B.4528-00

Drawing №

123456789Z

Drawing Revision Level

5.00

Supplier Inspection Results

USL

LSL

2.00

0.05

0.03

6.76

6.68

6.69

6.67

6.74

2.08

0.02

0.06

12.72 12.64 12.68 12.71 12.65 12.67 12.72

2.10

0.05

0.02

5.05

2.30

4.98

Autom. Autom.

6 7

For all SRC, Key and/or Safety Critical Dimensions mark this field with a "X". The Cpk Value will change to ≥ 1.67

Positive & Negative Tolerances

These Upper & Lower Autom. Autom. Specification Limits will be Autom. Autom. automaticity generated, No Autom. Autom. input required

Autom. Autom.

Document: QD-FAIR-Rev.1.0

Document: QD-PSRG-Rev.1.0

5.05

6.71 6.68

5.03 5.01

4.98

5.04

Cp >

SwissTech Results Only FAI FAI Cpk ≥ Result Sample Sample Result ↓ 1 2 1.68 Fail 6.73 6.69 PASS 1.67 1.24 Fail 12.71 12.64 PASS 1.33 1.69 PASS 4.98 5.02 PASS 1.67

Cpk↑ Dimensional results for all required PPAP samples

101

Inspec. Date Subm. Date Final Result Review Date

25 September 2014 30 September 2013 Impr. Required 02 October 2013

Capability Results

Sample 5

3 Print zone No. ③

Jean Paul Schwartzenberg

Sample 4

12.70

2 Print zone No. ②

Zolikon

Verified By (SwissTech)

Sample 1

6.71

Vendor №

Facility Location

- Tol.

Preud'homme d'Hailly de Nieuport

+ Tol.

1 Print zone No. ①

Nominal value

Item No.

Description for print zone or special notes

Supplier [name]

Specifications Critical Dim. Mark with "X"

Performed By [name] Jacque van Nassau

CpK Capability Result for Non- critical dimensions requires a CpK ≥ 1.33 for all SRC Key and/or safety critical dimensions require a CpK ≥ 1.67

Sample 3

Air Brake Disc / Rotor

Sample 2

Part Description

REPORTING INFORMATION

Cpk↑

Autom.

Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑ Cpk↑

-Tol. Impr. Req. on Zone ① Cpk Impr. Req. on Zone ②

Autom.

Cp Calculations Autom. Result on allCpk↑ dimensions Autom. requires Cpk↑ >2.00

Comments / Recommendations

Autom. SwissTech will prove the measurements

Autom.

Autom. Autom.

Fee space for additional comments / Recommendations

Autom.

The FAI Result Pass / Fail, will be automatically generated. Autom. Autom. No input required

Autom.

www.SwissTech-Automotive.ch

PAGE 1 / 1

13.5

41 | 5 2

14. RECORDS OF MATERIAL / PERFORMANCE TEST RESULTS

14.1

Material Test Results The supplier shall perform tests for all parts and product materials when chemical, physical, or metallurgical requirements are specified by the design record or Control Plan ď&#x201A;§ For products with SwissTech-developed material specifications and/or an SwissTech-approved supplier list, the supplier shall procure materials and/or services from suppliers on that list

14.2

Performance Test Results The supplier shall perform tests for all parts or product materials when performance or functional requirements are specified by the design record or Control Plan

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

Document: QD-PSRG-Rev.1.0

Material Specifications No.

www.SwissTech-Automotive.ch

Document: QD-PPAMR-Rev.1.0

Preud'homme d'Hailly de Nieuport

Zolikon

Performed by [name]

Location 101

Supplier №

Signature

Job Title

Material Results shall include: - The name of the laboratory that conducted the test - The type of test that was conducted - The number, date, and specification to which the part was tested - The actual test results

Specifications

Date

Performance Date (Original)

Jacque van Nassau

Key Contact

Note: When an external laboratory is used, the supplier shall submit the test results on the laboratory letterhead or the normal laboratory report format

(DD / MM / YY)

Date

ADMINISTRATION DETAILS Latest Rev. Level Supplier [name] Laboratory [name]

123456789Z

IN-HOUSE TESTING

OUTSIDE

Verified By [name] Jean Paul Schwartzenberg

Type of Test

Laboratory

Air Brake Disc / Rotor

Part Description / Product Name Drawing №

02 October 2013

Yes

Result meet Requirements

30 September 2013

Submission Date

+41 76 6789 001

Business Phone №

4DB.12B.4528-00 ℗

Part Number No.

14.3

4DB.12B.4528-00 ℗

SwissTech Part №

PRODUCTION PART APPROVAL - MATERIAL RESULTS

REV.

DOC. CODE QD-PPAMR-I

42 | 5 2 Appendix 14. Production Part Approval – Material Results

PAGE 1 / 1

43 | 5 2

15. Initial Process Study 15.1

What is it? A set of tools used to understand process capability.

15.2

Objective or Purpose  To evaluate the performance of your process as compared to specification limits.  To determine if the production process is likely to produce product that will meet customer requirements.

15.3

Applicability 1. To establish baseline capability. 2. To validate process improvements.

(Examples of Process Capability Charts)

15.4

Steps for Determining Process Capability 1. Decide on the product or process characteristic to be assessed a. Required for all critical characteristics b. If no critical characteristics exist, SwissTech reserves the right to require demonstration of initial process capability on other characteristics 2. Validate the specification limits (by talking to Customers, suppliers, controlling agencies) Why? a. They may not represent what the customer truly desires/needs. b. May contain “guard banding” as a result of past problems or measurement error. c. They may be based on previous designs and no longer be valid. 3. Validate the measurement system through the appropriate MSA Why? If there is significant error in your measurement system, then decisions are influenced by the error not just the measurements themselves. 4. Collect data and consider the following:  Short term data Free of special causes Collected across a narrow inference space i.e. one shift, one machine, one operator.  Long term data Subjected to the effects of both random and special cause variation Collected across a broad inference space i.e. multiple shifts, machines, operators, etc.  Rational sub-grouping A group of units produced under the same set of conditions Mean to represent a “snapshot” of the process -

Document: QD-PSRG-Rev.1.0

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44 | 5 2

Assess data characteristics  Examine the shape of your data. Is it what you would expect? If not, investigate. The shape of your data is important for determining which type of Capability Analysis applies. Mean StDev N

14.87 3.088 100

19.98 1.713 100

Mean StDev N

20.19 18.87 100

Frequency

14 16 Mfg Hours

Bimodal 6.

Mean StDev N

Histogram of Mfg Hours

Histogram of Mfg Hours 20

20 Mfg Hours

-15

Normal Data

30 45 Mfg Hours

Skewed Data

Assess process stability in order to understand how your process behaves over time. Control charts are the recommended tool. Capability is only valid when the process being studied is stable! Control Chart Examples

Process is stable and in control

Process is not stable and therefore not in control

Calculate process capability  Calculate the appropriate statistical metrics in order to determine how the “Voice of the Process” compares to the “Voice of the Customer.” Capability Metrics: PPM, DPMO, Cp, Cpk, Pp, & Ppk ; Sigma Levels (Z Scores)

Process is capable

15.5

Process in not capable

The initial process study should be focused on variable, not attribute data  Assembly errors, test failures, and surface defects are examples of attribute data, which is important to understand, but is not covered in this initial study.  To understand the performance of characteristics monitored by attribute data will require more data collected over time.  Unless approved by an authorized SwissTech representative, attribute data are not acceptable for PPAP submission.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

45 | 5 2

15.6

Capability Indices

Cp Cpk PP Ppk Note:

(USL – LSL)

Relates short term (within subgroup) standard deviation to tolerance

6*sshort-term

Sometimes called “Entitlement,” meaning it is the best the current process can do, if centered

Min{(USL – X), (X – LSL)}

3*sshort-term (USL – LSL)

Relates short term mean & short term (within subgroup) standard deviation to tolerance Only tells you about the nearest spec limit; doesn’t tell anything about the other side Relates long term (overall) standard deviation to tolerance

6*slong-term Min{(USL – X), (X – LSL)}

3*slong-term

Relates mean & long term (overall) standard deviation to tolerance Only tells you about the nearest spec limit; doesn’t tell anything about the other side

Pp/Ppk are used to measure actual process performance Cp/Cpk are used to estimate potential process capability

15.7

Cpk predicts capability  Based on short term within subgroup variation.  Does not include the effect of process variability between subgroups.

15.8

Cpk should be used when:  Developing new parts  Revising specifications on a part  Materials, processes, manufacturing location, or equipment have significantly changed  Material suppliers have changed (include certificate of analysis)

15.9

Ppk indicates past performance  Based on long term total variation.  Unlike Cpk, Ppk is not limited to variation within subgroups.  However, Ppk cannot isolate within subgroup variation from between subgroup variation.  When calculated from the same data set, Cpk and Ppk can be compared to analyze the sources of process variation.

15.10

Ppk should be used when:  The supplier is new to SwissTech, but has already been manufacturing a part.  The supplier is existing, but has produced a number of nonconforming parts.

15.11

Difference between Cp / Cpk  Cp – determines capability of producing to specification  Cpk – same as Cp, but also measures how centered the process is It is important to look at both!

Document: QD-PSRG-Rev.1.0

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46 | 5 2

15.12

Acceptance Criteria Acceptance criteria for critical vs. non-critical characteristics

Red (Bad) Yellow (OK) Green (Good)

Critical

Non-Critical

<1.33

<1.00

1.33-1.67

1.00-1.33

>1.67

>1.33

Decision

Cpk must be greater than or equal to 1.67 for critical processes Cpk must be greater than or equal to 1.33 for non-critical processes

15.13

Checklist  Ensure that the results are acceptable, and that the process is stable and capable of producing a quality part.  PPAPs should only be approved if the capability is greater than 1.67 for critical dimensions and greater than 1.33 for non-critical dimensions.  More information about capability is available in the Appendix at the end of this presentation.

16. QUALIFIED LABORATORY DOCUMENTATION The purpose of this record is to verify that the supplier has used an Accredited Laboratory/Testing Facility to perform all Material, Functional, and Performance testing called out on the Drawing and Control Plan.  Inspection and testing for PPAP shall be performed by a qualified laboratory as defined by SwissTech requirements (e.g., an accredited laboratory).  The qualified laboratory (internal or external to the supplier) shall have a laboratory scope and documentation showing that the laboratory is qualified for the type of measurements or tests conducted. When an external laboratory is used, the supplier shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date(s) of the tests, and the standards used to run the tests shall be identified.

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

Preud'homme d'Hailly de Nieuport

Performed by [name]

Zolikon 101

Supplier №

Test Description

Signature

Module Test Results shall include: - The name of the laboratory that conducted the test - The type of test that was conducted - A description of the test - The parameters tested - The actual test results

Parameters Tested

Job Title

Description of Supplier Test Results

Date

Performance Date (Original)

Jacque van Nassau

Key Contact [name]

Note: When an external laboratory is used, the supplier shall submit the test results on the laboratory letterhead or the normal laboratory report format

Location

ADMINISTRATION DETAILS Latest Rev. Level Supplier [name] Laboratory [name]

123456789Z

IN-HOUSE TESTING

OUTSIDE

Jean Paul Schwartzenberg

Document: QD-PPAMT -Rev.1.0

Verified By [name]

Type of Test

Laboratory

Air Brake Disc / Rotor

Part Description / Product Name Drawing №

02 October 2013

Yes

Result meet Requirements

30 September 2013

Submission Date

+41 76 6789 001

Business Phone №

4DB.12B.4528-00 ℗

Part Number No.

16.1

4DB.12B.4528-00 ℗

SwissTech Part №

PRODUCTION PART APPROVAL - MODULE TEST

REV.

DOC. CODE QD-PPAMT-I

47 | 5 2 Appendix 11. Production Part Approval – Module Test

PAGE 1 / 1

48 | 5 2 17. APPEARANCE APPROVAL REPORT (AAR) 17.1

What is it? A report completed by the supplier containing appearance and color criteria

17.2

Objective or Purpose  To determine if the production process is likely to produce product that will meet customer requirements.  To demonstrate that the part has met the appearance requirements on the design record

17.3

Applicability Prior to tooling for production

Note: Typically only applies for parts with color, grain, or surface appearance requirements 17.4

Appendix 13. – (Appearance Approval Report – AAR)

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

APPEARANCE APPROVAL REPORT

DOC. CODE

REV.

QD-AAR-I

Part Number 4DB.12B.4528-00 ℗

Section 1: Component and Supplier Information Part Description

Air Brake Disc / Rotor

Performed By [name] Jacque van Nassau

SwissTech Part №

4DB.12B.4528-00 ℗

Maunfacturing (location)

Supplier Sourcing & Texture Information

Application

List all first surface tools, graining Source(s), grain type(s), and grain

Supplier [name] Reason For Submission

First Production Shipment Prototype Shipment

Rev. Level

123456789Z

Verified By (SwissTech)

Preud'homme d'Hailly de Nieuport

27 September 2013

Supplier №

Zolikon

Drawing №

MERCEDES-BENZ

Inspec. Date

Rev. Level Date

27 June 2013

To be completed by Supplier QA Engineer

Review Date

Jean Paul Schwartzenberg

Engineering Change Tooling: transfer, replacement, refurbishment

101 Pre-Texture Evaluation

02 October 2013

Re-submission Sub-supplier Change Other Specify

Section 2: Appearance Evaluation Pre-Texture Evaluation Correct and Proceed

Supplier Sourcing and Texture Information

SwissTech Representative Signature and Date

Date (DD / MM / YY) Colour Suffix

Material Type Master Number

Alphanumeric or numeric color identification

Enter alphanumeric master identification

Color Shipping Suffix

Correct and Resubmit Date (DD / MM / YY)

Identify first surface finish and substrate (e.g. paint / ABS)

Color part number suffix or color number

Approved to Texture Date (DD / MM / YY)

Section 3. Colour Evaluation Tristimulus Data

Colour Suffix

Master Number

Master Date

Material Type

HUE

Material Source

DL* Da* Db* DE* CMC

RED

Tristimulus Data

Master Date

List numerical (colorimeter) data of submission part as compared to the customer-authorized master "X"

Enter the date on which the master was approved

YEL

GRN

Material Source Identify first surface and substrate suppliers

Value BLU

Chroma

Gloss

Metallic Brilliance

LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW

Colour Shipping Suffix

Part Disposition

Hue, Value, Chroma, Gloss, and Metallic Brilliance

Part Disposition

Visual assessment by SwissTech

To be determined by SwissTech (approved or rejected)

Comments

Supplier Signature

SwissTech Use Only Comments

Approved Verified By [name]

Jean Paul Schwartzenberg

Document: QD-AAR-Rev.1.0

Document: QD-PSRG-Rev.1.0

Approved with Deviation Signature

Rejected E-mail

Info@SwissTech-Automotive.ch

Date

02 October 2013

www.SwissTech-Automotive.ch

PAGE 1 / 1

49 | 5 2

50 | 5 2

18. Sample production Parts 18.1

What is it? Actual samples that reflect the parts documented in the PPAP.

18.2

Objective or Purpose Confirm cosmetic or functional part approval.

18.3

When to use it Sample parts should be delivered WITH the PPAP submission The sample parts provided should be the same parts measured for the dimensional results Default quantity for all submissions is 3 parts unless otherwise requested

18.4

Sample production parts MUST be properly identified Include the following information on the part label:  Date parts were packed  SwissTech part number  Quantity  Serial number  Supplier part number (optional)  Part description  Country of origin  Indication of RoHS compliance  Approval markings (UL, CE, etc.) where applicable

19. PPAP Summery   

The Production Part Approval Process is an extensive approval process for new or changed designs or processes It is very formalized, so it inevitably causes some administrative work Later changes to the product or process can be expensive and time-consuming!

Document: QD-PSRG-Rev.1.0

www.SwissTech-Automotive.ch

51 | 5 2 Appendix 14. PPAP Submission Checklist Part I (shown below)

PPAP SUBMISSION CHECKLIST (part I)

DOC. CODE

REV.

QD-PSC-I

PART Number 123456789X

PRODUCT INFORMATION Part Description

REPORTING INFORMATION

Brake Disc/Rotor

Performed By (Name)

Jacque van Nassau

Part Number

123456789X

Supplier (Name)

Preud'homme d'Hailly de Nieuport

SwissTech Part Number

+T.987654321

Facility Location

Zolikon

Drawing Number

123456789Z

Drawing Revision Level

ITEMS SUBMITTED Part Submission Warrant 1 Correct part name and part number 2 Correct drawing change level and revision dates 3 Weight of the part in kg. to 3 decimal places 4 Additional EC and/or SMCR number noted (if required) 5 Production process and production rate given 6 Remainder of form filled in correctly 7 KEG submission location information is correct (1 Warrant per each KEG location) 8 Action plan(s) to address discrepancies included (for Interim Approval) Drawing and Change Documents 1 Released drawing at latest change level and matches warrant 2 Ballooned drawing 3 All characteristics ballooned and numbered (including Notes) 4 Approved SMCR or ECR attached (if applicable) DFMEA: (if available) 1 Complies to AIAG FMEA Manual (Current Revision) 2 Blue print date and level match 3 All Special Characteristics (DC/SC/CC) addressed 4 Highest RPNs/severity addressed (Target RPN<100) 5 Addresses typical / historical failure modes Process Flow Diagram 1 Diagram accurately reflects process, including rework and inspection stations 2 Header information accurate 3 All relevant process and product characteristics (DC/SC/CC) are listed and 4 Obvious Link between Flow, PFMEA, and Control Plan (same step numbers, names, process) PFMEA (Process) 1 Complies to AIAG FMEA Manual, with appropriate rankings 2 Blue print date and level match 3 All DC/SC/CCs addressed 4 Highest RPNs/severity addressed (Target RPN<100) 5 Address typical / historical failure modes 6 Connection to the DFMEA failure modes and severity levels Dimensional Results 1 Report complies to AIAG format or equivalent 2 Correct part number and change level 3 All marked dimensions match with the ballooned print and are within the spec. 4 OK / NOT OK column checked properly 5 The supporting documents dated within six (6) months; 6 Dimensional Data within three (3) months Material Tests 1 Report complies to AIAG format or equivalent 2 All test results reported per specification or print 3 All results conform with specs and have they been performed within six (6) months 4 All tests performed at an accredited facility, with proof of accreditation and scope Performance Tests 1 Report complies to AIAG format or equivalent 2 All test results reported per specification or print 3 All results conform with specs and have been performed within six (6) months 4 All tests performed at an accredited facility, with proof of accreditation and scope Capability Studies 1 Studies performed per AIAG standards, or equivalent 2 Part number and change level correct 3 All Special Characteristics have Cpk studies per the GSQM requirements 4 The data is normally distributed and meets the GSQM Ppk (long term) / Cpk (short term) requirements 5 Studies performed within six (6) months of submission date Gage R&R Studies 1 Report complies to AIAG format or equivalent 2 Gage name and characteristics properly identified 3 Studies performed per acceptable AIAG method 4 Studies performed on all gages used on SC/DC/CC features, at a minimum (including online gages and testers) 5 The studies were done within six (6) months 6 All the results meet AIAG guidelines

Document: QD-PSRG-Rev.1.0

Verified By (SwissTech) Jean Paul Schwartzenberg

Yes

N/A

Vendor No.

123

Perform. Date Subm. Date Subm. Level Review Date

29 September 2013 30 September 2013 3 02 October 2013

EXPLANATION

x x x x x x x x x x x x x x x x x x x x x

x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

www.SwissTech-Automotive.ch

PAGE 1 / 2

19.1

52 | 5 2 Appendix 15. PPAP Submission Checklist Part I (shown below) DOC. CODE

REV.

QD-PSC-I

PPAP SUBMISSION CHECKLIST (part II)

PART Number 123456789X

ITEMS SUBMITTED Control Plan 1 Report complies to AIAG format or equivalent 2 Plan type is clearly identified (Prototype, Safe Launch/Preproduction, Production) 3 All SC/DC/CCs and other pertinent characteristics are identified 4 Controls type and frequency are adequate 5 Annual revalidation activities are included 6 Offline or offsite processes are included (i.e. rework, warehouse activity, receiving, shipping) 7 Defect masters, test shills, colour masters, and gold standards are identified (where applicable) Appearance Approval Report 1 The report meets specified requirements 2 The report has been approved by KEG and KEG's Customer Bulk Material 1 The PPAP contains a Bulk Materials Checklist, and it meets requirements Sample Parts 1 Samples are included (if requested) Checking Aids 1 Checking aids are included (if requested) Customer Specific Requirements 1 Additional customer required documents are included (i.e. GMW3059 materials Pri requirement) nt 2 Additional print required testing, for quality level of part. (i.e. Seal Testing, Electrical, Solderability, HiPot, others) 2 Any above that are YES has the calibration of the test equipment been confirmed 3 All results conform with specs and have been performed within six (6) months Packaging Information 1 The submission includes packaging plan and sample label 2 The packaging is acceptable to the KEG receiving plant(s) EVL / IMDS 1 ELV/IMDS Form "C' included in the PPAP and complete 2 Approval obtained from IMDS coordinator Capacity Verification or Preliminary Capacity Study 1 Equalized capacity is greater than CPV for each operation 2 Corrective Action attached if required Product Characteristics Matrix 1 Form filled out and content correct 2 DCs match Control Plan and Drawing Sub-Supplier(s) 1 Sub-supplier PSWs are included and fully approved (no interims) 2 Interim approved Sub-supplier PPAP's require a corrective action plan to be included with the submission 3 Full PPAP included for Sub-suppliers responsible for SC/DC/CC designated features 4 Critical process Sub-suppliers are OEM, KEG, or KEG Customer approved (if required) 5 Sub-suppliers are ISO 9000 certified or ISO/TS 16949 compliant 6 Sub-suppliers meet capacity requirements 7 Sub-suppliers (name and LOCATION) matrix is included, if multiple Sub-suppliers Document: QD-PSC-Rev.1.0

Document: QD-PSRG-Rev.1.0

Yes

N/A

EXPLANATION

x x x x x x x

www.SwissTech-Automotive.ch

PAGE 2 / 2

19.2

53 | 5 2

THE TIME HAS COME…

Distributed by Bergstrasse 31, CH-8703 Küsnacht, ZH Zürich Switzerland Info(at)SwissTech-Automotive.ch www.SwissTech-Automotive.ch Document: QD-PSRG-Rev.1.0